Process Control & Automation Solutions
Reliable PLCs, VFDs, instrumentation, and SCADA systems for continuous process industries including oil & gas, chemical processing, water treatment, and power generation.
Optimize Your Process Operations
ElectroWell provides comprehensive process automation solutions that ensure consistent product quality, regulatory compliance, and operational safety across your plant operations.
Process Control Applications
Chemical Processing
Temperature, pressure, and flow control for reactors, distillation columns, and batch processes.
- PID loop control
- Batch recipe management
- Hazardous area certification
Water & Wastewater
Pump control, level monitoring, and treatment process automation.
- VFD pump control
- SCADA integration
- Remote telemetry
Oil & Gas
Upstream, midstream, and downstream automation systems.
- SIL-rated safety systems
- Modbus RTU/TCP
- Hazardous location rated
Power Generation
Turbine control, boiler management, and electrical distribution.
- Redundant controllers
- Distributed control systems
- Real-time monitoring
Process Automation Products
Process PLCs & PACs
- Siemens S7-1500 Advanced: High-performance process controllers with PROFINET and PROFIBUS
- Allen-Bradley ControlLogix: Scalable PACs for large distributed control systems
- Schneider Modicon M580 ePAC: Ethernet-based process automation with cybersecurity features
- Emerson DeltaV: Native distributed control system (DCS) for continuous processes
- Omron CJ2M: Modular PLCs with analog processing for hybrid control
Variable Frequency Drives for Process Control
- Danfoss VLT HVAC Drive FC 102: Optimized for pumps, fans, and compressors in HVAC/R applications
- Vacon NXP Process Drive: Common DC bus drives for multi-motor coordination
- Allen-Bradley PowerFlex 755: High-power drives with advanced process control features
- Siemens SINAMICS G120C: Compact drives for pumps and fans with IO-Link
- ABB ACS880: Industrial drives with ultra-low harmonic (ULH) technology
Process Instrumentation
- Temperature transmitters (RTD, Thermocouple)
- Pressure transmitters (0-10V, 4-20mA)
- Flow meters (magnetic, ultrasonic, Coriolis)
- Level sensors (radar, ultrasonic, capacitance)
- Analytical instruments (pH, conductivity, dissolved oxygen)
Process Control Architectures
Distributed Control Systems (DCS)
Full-featured DCS for large-scale continuous processes with:
- Redundant controllers and I/O
- Advanced regulatory control (PID, cascade, feedforward)
- Asset management and diagnostics
- Batch management (ISA-88 compliant)
- Alarm management (ISA-18.2 compliant)
SCADA Systems
Supervisory Control and Data Acquisition for remote monitoring:
- Multi-site monitoring and control
- Historical data logging and trending
- Report generation and KPI dashboards
- Mobile/web access for remote operations
- Integration with MES and ERP systems
PLC-Based Process Control
Cost-effective automation for small to medium process applications:
- Modular I/O expansion
- Built-in PID control blocks
- Modbus, HART, FOUNDATION Fieldbus integration
- HMI/SCADA connectivity
Industry-Specific Solutions
Chemical & Petrochemical
Key Requirements: Batch control, recipe management, hazardous area certification (Class I Div 2, ATEX, IECEx)
Recommended Products:
- Siemens S7-1500F fail-safe controllers
- Allen-Bradley Kinetix servo systems for precise dosing
- Explosion-proof HMIs and operator panels
- Safety-rated I/O modules for emergency shutdown (ESD)
Oil & Gas Production
Key Requirements: Remote monitoring, RTU/SCADA, SIL 2/3 safety systems, harsh environment operation
Recommended Products:
- Schneider Electric M580 with hot standby redundancy
- Allen-Bradley GuardLogix safety PLCs
- Cellular/satellite modems for remote telemetry
- Ruggedized enclosures (NEMA 4X, IP66)
Water & Wastewater Treatment
Key Requirements: Pump control, level regulation, chemical dosing, energy optimization
Recommended Products:
- Danfoss VLT drives with cascade PID for pump stations
- Omron NJ/NX series PLCs with EtherCAT I/O
- Wireless level transmitters for tank farms
- SCADA systems with GIS integration
Power Generation
Key Requirements: High availability, redundancy, real-time control, NERC CIP compliance
Recommended Products:
- Allen-Bradley ControlLogix with redundant processors
- Siemens PCS 7 distributed control system
- Ethernet/IP fiber optic networks
- Cybersecurity modules and firewalls
Food & Beverage Processing
Key Requirements: Washdown design, CIP/SIP automation, FDA compliance, recipe management
Recommended Products:
- Stainless steel VFDs with IP69K rating
- Washdown HMIs (stainless steel, glass front)
- Food-grade servo motors for filling/packaging
- 21 CFR Part 11 compliant software
Process Safety & Compliance
ElectroWell provides safety-rated components for critical process applications:
Safety Instrumented Systems (SIS)
- SIL Rated PLCs: Allen-Bradley GuardLogix, Siemens S7-1500F (up to SIL 3/PLe)
- Emergency Shutdown: Redundant safety I/O, safety relays, E-stop circuits
- Burner Management: Flame monitoring, gas train control, purge sequences
- High Integrity Pressure Protection (HIPPS): Rapid pressure relief systems
Regulatory Compliance
- IEC 61508: Functional safety standard for safety instrumented systems
- IEC 61511: Process industry safety lifecycle (SIL verification)
- ISA-88: Batch control standards for recipe management
- ISA-95: Enterprise-control system integration
- ATEX/IECEx: Explosion protection for hazardous areas
- FDA 21 CFR Part 11: Electronic records and signatures (pharmaceutical)
Communication Protocols for Process Control
Our products support all major industrial communication protocols:
Fieldbus Protocols
- FOUNDATION Fieldbus (H1, HSE)
- PROFIBUS-DP/PA
- Modbus RTU/ASCII
- DeviceNet
- HART (wired & wireless)
Industrial Ethernet
- PROFINET
- Ethernet/IP
- Modbus TCP/IP
- OPC UA (unified architecture)
- EtherCAT
Energy Management & Optimization
Reduce operational costs with intelligent process control:
- VFD Energy Savings: 30-50% energy reduction on pumps, fans, and compressors
- Demand Response: Automatic load shedding during peak pricing periods
- Power Monitoring: Real-time tracking of kWh consumption by process area
- Soft Starters: Reduce inrush current and mechanical stress on motors
- Power Factor Correction: Minimize reactive power penalties
Why Choose ElectroWell for Process Automation?
? Process Industry Experience
Decades of experience supplying automation to chemical plants, refineries, and utilities.
? Safety-Rated Products
Full range of SIL-rated controllers, I/O modules, and safety devices for critical applications.
? Global Support
Worldwide shipping with local technical support for system integration and troubleshooting.
? Technical Expertise
Engineers available to help with loop tuning, network design, and protocol selection.
Need Process Control Expertise?
Our engineers can help you select the right automation components for your process
Get Technical AssistanceOr email us at support@electrowell.com with your application details
Case Studies
Water Treatment Plant Modernization
Challenge: Aging relay-based pump controls with no remote monitoring capability.
Solution: Schneider Modicon M580 PLC with Danfoss VFD pump control and Citect SCADA.
Results: 40% energy savings, predictive maintenance alerts, remote access for operators, 99.9% uptime.
Chemical Batch Process Upgrade
Challenge: Manual recipe management causing batch-to-batch variability.
Solution: Allen-Bradley ControlLogix with FactoryTalk Batch and PanelView Plus HMIs.
Results: ISA-88 compliant batch control, electronic batch records, 75% reduction in quality deviations.