Process Control & Optimization Services

Operational Excellence

Is a Continuous Process.

“Operational Excellence is when each and every employee can see the flow of value to the customer, and fix that flow when it breaks down.”– Industry Week Magazine

NovaTech Engineering Services has delivered successful projects and peace of mind to the most respected process manufacturers in the world for over thirty years. In that time we’ve learned a lot about how to make a process facility more agile, productive, and profitable.  Our services offerings (available per project or as part of a Facets Support Agreement) combine the latest process automation technologies with decades of applications expertise to help you achieve ever-higher levels of safety, agility, and performance.  What follows is an overview of our proven process for developing, deploying, and continuously improving our process automation solutions.


Getting the most out of an investment in process automation requires a balanced integration of near-term ROI and long term agility.  This holistic approach requires a bit more thinking and planning at the outset, but pays huge rewards in terms of risk mitigation over the lifetime of an installation when the “unknown unknowns” begin to appear.  In this initial discovery phase, our engineers work with your team to determine basic system availability requirements, continuous control objectives and strategies, interlock and safety considerations, and document standards related to recipe, programming, sequencing, abnormal situation management, simulation, HMI, alarming, and testing.


Our network architecture and Control System Designs are built for rock solid reliability and maximum flexibility.  Our engineers design, fabricate, configure, and test all control system components before performing a detailed Factory Acceptance Test (FAT) or Installation Qualification  (IQ) to your specifications. At this point, the control system is either shipped directly to your facility, or our Applications Engineering team begins writing custom application code to your specifications.


Our proven design and coding techniques (including Alarm Design and Procedural Knowledge Capture) focus on abnormal situation management to ensure robust plant performance under all operating conditions.  Detailed design documents specify the operation and programming of each process unit, interactions between units, and the system as a whole.  This integrated approach improves operator effectiveness, plant safety, product quality, and new product introduction.


TotalVision Process graphics are developed with High Performance Human Machine Interface (HMI) principles to ensure operators are informed, not overwhelmed. Informational density and correct use of colors, trends and symbols improve operators’ understanding of the process and decision making while ensuring faster recovery from abnormal situations.


One of the most important aspects of our development methodology – and an important native functionality of the D/3 – is simulation.  By simulating process  I/O, process dynamics, equipment characteristics, and operator/HMI interaction, we can ensure that our applications perform to your expectations.  This helps ensure successful acceptance tests, on-time deliveries, efficient commissioning, smooth start-ups and thorough operator training.


This is often the most critical phase of a system deployment, so our Field Engineers make exhaustive Project Management preparations and are available 24/7 during deployment to insure that installation, commissioning, validation and system startup are successful.


Once your plant is up and running, the focus shifts to asset and change management.  Field equipment and system health are monitored by Asset Management software and ensured with Preventative Maintenance.  Flexible D/3 and FlexBatch software solutions allow staff members to modify virtually any process control strategy,  sequence program, procedure, or recipe attribute on-the-fly.  Furthermore, NovaTech process control system software provides online upgrade capability to facilitate version upgrade without process interruption.


Once a plant is up and running with proactive maintenance practices, several opportunities for greater efficiency emerge, including Process Analytics Dashboards, Energy and Utilities Management, and Loop Optimization.  Intuitive enterprise-level dashboards of plant and unit performance allow managers to efficiently allocate resources, perform root cause analysis, and track plant performance to strategic of business objectives.  Flexible solutions allow for easy modification as new insights and shifts in the business landscape drive performance goals.

  • Introducing FlexBatch 5.0

    FlexBatch integrates recipe management and the automation layer so operators can quickly and easily develop, scale up, modify and schedule batch manufacturing recipes for products ranging from beer to chocolate to specialty chemicals and more. FlexBatch delivers shorter time to first batch, reduced changeover times, increased throughput and production yield. New and existing products are brought to market faster and at lower cost, providing a strategic and financial advantage. Production staff can execute library procedures to overcome process upsets. All of which means a more nimble, responsive, and profitable process.

    July 5, 2017

  • Planning an Effective I/O Upgrade

    Reviewing the benefits, considerations, and steps required to migrate legacy I/O subsystems to NovaTech 8000.

    This webinar focused on NovaTech 16000 and Modicon Quantum, and touch on Siemens 505, Rockwell 1771, and Modicon 200.

    Topics Covered:
    * Hardware installation alternatives
    * Wiring options
    * Software considerations
    * Proven implementation strategie

    April 20, 2017

  • D3v15 Webinar

    The latest release of the D/3 Distributed Control System includes new configuration tools that make the system easier for new and existing users. The webinar covers building tags with MDL Builder, writing automation code with D3Edit, web-accessible History and Reports, features to facilitate migration to High-Performance HMI, and OSIsoft PI integration.

    March 24, 2016

  • D/3 Distributed Control System Overview

    This video introduces the D/3, the Distributed Control System trusted by many Fortune 100 companies to keep their global operations’ continuous and batch processes running smoothly and efficiently. Part one reviews the system architecture and configuration tools.

    November 21, 2014

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