A large semiconductor manufacturing client consumes large quantities of dangerous chemicals such as hydrofluoric and sulfuric acid. They originally purchased these chemicals in 55 gallon drums and then distributed the drums to each production area on an as needed basis. This process was labor intensive, consumed valuable space and exposed workers to additional risk. In addition, the unit cost of buying chemicals in 55 gallon drums was much higher than buying in bulk.

Plant management wanted to store the chemicals centrally in large 5,000 gallon tanks, then distribute them to 250 and 500 gallon tanks in process areas and then finally to each tool area they were consumed. However, they did not have a reliable method to control this type of process.

We collaborated with our client to develop a reliable process control system that achieved this goal. The solution combined a PLC based system, with touch screens for local control and integrated it all together into Wonderware HMI software. ACS designed and programmed the system to meet the strict requirements of this very demanding environment. By the time we completed the project there were over 150 remote terminal units situated around the plant that provided control to the entire system. At the time it was built, it was the largest PLC network in the northwestern US.