From feedstock to renewable gas—connected, safe and measurable operations.
TAS is the automation, instrumentation-integration and digital operations partner for biogas, CBG / Bio-CNG, RNG and CHP plants. We connect digesters, gas-upgrading skids, compressors, CHP engines and analyzers into one supervisory layer—PLC/SCADA, historian, alarms and KPI dashboards—so owners, process OEMs and EPCs can run every site with reliable, auditable data.
AD · CBG · RNG · CHP PLC / SCADA & Historian Multi-site visibility
Digester stabilityTemp · level · pressure
Gas qualityCH₄ · H₂S · moisture
Output & uptimeCBG · kWh · availability
One operating view
Feedstock, digesters, gas, CBG and CHP on a single timeline.
Earlier warnings
Trend-based alerts on temperature, gas quality and equipment health.
Reconciled numbers
Meter-to-report traceability for production and dispatch.
Vendor-neutral
Integrates OEM skid PLCs, analyzers and meters across protocols.
ESG-ready data
Validated, time-stamped records for sustainability reporting.
Value Chain
One connected operating layer across the entire biogas value chain
Most biogas sites run several islands of automation—a digester PLC, an upgrading-skid PLC, a compressor panel, a CHP controller and standalone analyzers. TAS connects them, contextualises the data by asset and process stage, and turns it into one dependable operating picture.
Conceptual process—not a P&ID. Actual equipment, instrumentation and safety design are defined by the plant owner, process licensor / OEM and EPC for each project.
Feedstock reception & dosing
Weighbridge tickets, supplier and batch IDs, storage and dosing flow.
Pretreatment
Shredding, mixing, hygienisation / heating; pump and motor status.
Anaerobic digesters
Temperature, level, pressure, mixers, heating loops; pH and lab VFA/TAC.
Raw biogas storage
Gas-holder level and pressure, raw-gas flow and composition.
Gas cleaning / upgrading
Desulphurisation, drying, membrane / PSA skid status and product-gas quality.
CBG / CHP / grid
Compression, cascade and dispensing in kg—or CHP kWh, heat and availability.
Parallel branch · Digestate management: volumes, storage levels, separation and bio-fertiliser dispatch records.
Safety bypass · Flare: flare operation and run-hours are monitored and logged; flare control stays with the OEM / safety system.
Operating Reality
The practical challenges biogas operators face every day
Biogas plants are living processes connected to mechanical, electrical and gas systems from many vendors. Without connected data, problems surface late—as lower gas yield, unplanned downtime or reports that don’t reconcile.
Changing feedstock & OLR
Seasonal and supplier variation shifts organic loading and gas potential.
Digester stability
Temperature drift, foaming or acidification signals are spotted too late.
Methane yield visibility
Yield per tonne is hard to track without trusted input and output data.
Variable gas quality
H₂S, moisture and CH₄ swings stress upgrading, engines and compressors.
CHP reliability
Engine trips and derates reduce power export and heat recovery.
Compressor uptime
CBG output depends on compressor health, cascade pressure and dispensing.
Meter reconciliation
Raw-gas, product-gas and dispatch meters rarely agree without normalisation.
Emissions & methane slip
Leak events, flaring and slip need consistent records, not estimates.
Offline, multi-vendor data
OEM panels, spreadsheets and logbooks with no single source of truth.
Regulatory reporting
Monthly reports compiled manually from many sources, under time pressure.
Capabilities
What TAS delivers for biogas, CBG and CHP plants
TAS provides OT automation, PLC/SCADA engineering, industrial communication, ADVAIT historian and OTConneX monitoring, WP500 edge gateways where appropriate, analytics, alarm workflows and multi-site visibility. We work alongside your process licensor, OEMs and EPC—TAS does not design fermentation biology or act as the biogas process licensor or EPC.
Feedstock traceability & dosing
Link what goes in to what comes out.
Weighbridge and batch / supplier IDs
Storage inventory and dosing flow
Feedstock mix by digester and shift
Digester monitoring
Stability signals in one trend view.
Temperature, pressure, level, mixers, heating
pH / ORP where instrumented
Lab VFA, TAC and VFA/TAC entries alongside online data
Biogas production & flow normalisation
Volumes you can defend.
Totalised raw-gas and product-gas flow
Actual-to-standard volume (Nm³) only with valid temperature / pressure inputs
Reference conditions configured per project standard
Gas quality from installed analyzers
Composition tracked against limits.
CH₄, CO₂, O₂, H₂S
Moisture / dew point
Analyzer status, calibration flags and data quality
Upgrading skid & CBG integration
OEM skids brought into one view.
Membrane / PSA skid status and product quality
Compressor run, trips, pressures and hours
Cascade storage and dispensing (kg)
Safety-system status monitoring
Visibility only—never control.
Flare, gas holder and ventilation status
Fixed H₂S / CH₄ detection alarm states
Shutdown / trip status and event logging
CHP / genset & energy outputs
Power and heat accounted for.
Engine status, load, trips and run-hours
kWh generated, exported and consumed
Recovered heat where metered
Alarms, events & historian
Every event, time-stamped and searchable.
Prioritised alarms and acknowledgement
ADVAIT historian with data-quality flags
Sequence-of-events review after trips
Plant KPIs & shift reports
Reports that build themselves.
Daily, shift and monthly production reports
Specific yield, availability, consumption
Export to Excel / PDF and ESG data sets
Remote asset monitoring & maintenance workflows
OTConneX and WP500 edge connectivity (where appropriate) give engineers secure, read-only visibility of remote and multi-site plants, with run-hour and condition-based maintenance triggers pushed to your CMMS.
PLC / SCADA engineering & integration
Balance-of-plant PLC programming, SCADA/HMI development and protocol integration (Modbus TCP/RTU, OPC UA, MQTT, industrial Ethernet) to the owner’s specification—coordinated with OEM skid control philosophies.
Safety boundary: Independent safety instrumented systems (SIS), fixed gas detection and OEM safety interlocks remain authoritative. TAS monitoring, analytics and dashboards never bypass, override or replace these safeguards.
Operations Cockpit
See the whole plant at a glance
An example of the role-based cockpit TAS configures for plant managers and shift teams—production, gas quality, digester health, CBG and CHP output and active alarms on one screen, drilling down to equipment and trends.
Illustrative mock-up with sample values only—not data from, or a performance claim for, any TAS installation. Actual screens, KPIs and calculations are configured per project.
Role-based views
Shift operator: live process, alarms, handover notes
Gas-engine power and heat for self-use or export, with availability tracking.
kWh exportEngine tripsHeat recovery
OEM skids, one view
Upgrading and compressor packages integrated without changing OEM control logic.
Architecture
A pragmatic five-layer architecture
Deployable at the edge, on-premise, in the cloud or hybrid—with segmented, encrypted connections, an ISA-95-style asset hierarchy and IEC 62443-aligned OT practices. The digital layer supervises and reports; it does not replace control loops or safety logic.
Reference architecture—adapted to each site’s existing systems, connectivity and owner IT/OT policy.
Enterprise & ESG
ERP, CMMS and ESG / regulatory data exports from validated records.
Analytics & workflows
KPI dashboards, alarm workflows, shift reports and a fleet / multi-site portal.
Site SCADA & historian
On-prem SCADA/HMI, ADVAIT historian and OTConneX monitoring.
Sensors, meters, analyzers, OEM skid PLCs, SIS and gas detection.
Edge · On-prem · Cloud · HybridZones & conduitsEncrypted linksRead-only by defaultISA-95 asset model
KPIs
Metrics that matter—with a clear basis for each
Every KPI is only as good as its source. TAS documents the instrument, calculation and reference conditions behind each number, and flags data quality where inputs are missing.
Feedstock input
t / day
Weighbridge and dosing records, by supplier and digester.
Organic loading rate
kg VS / m³·d
Calculated where feed flow and lab solids data are available.
Digester temperature & stability
°C · deviation
Online temperature with lab VFA/TAC context.
Biogas production
Nm³ / day
Normalised only with valid T/P inputs and configured reference.
Methane content
% CH₄
From installed analyzers, with status and calibration flags.
H₂S concentration
ppm
Raw and treated gas, against equipment limits.
CBG yield
kg / day
Compression, cascade and dispensing totals reconciled.
Energy exported
kWh · heat
CHP generation, export and auxiliary consumption.
Specific yield
Nm³ / t
Methodology-dependent; basis (wet, VS, CH₄) stated on every report.
Plant availability
%
By section: digestion, upgrading, compression, CHP.
Methane losses & leak events
events · flare h
Logged events and flare hours from installed detection and meters.
Consumption, maintenance & reconciliation
kWh · h · Δ%
Parasitic load, run-hours and meter-to-meter balance.
Biogas is flammable and can contain toxic H₂S. TAS designs digital systems that respect independent protection layers and the project’s hazardous-area design.
What the TAS digital layer does
Process automation and supervisory monitoring of balance-of-plant
Only those remote controls explicitly permitted by the owner and OEM—read-only by default
Data provenance: source tag, timestamp, unit and quality flag on every value
Historian validation, gap detection and audit trail of edits and acknowledgements
Configurable reports aligned to the owner’s compliance obligations
What remains independent & authoritative
Safety instrumented systems and emergency shutdown logic
Fixed gas detection and its alarm / trip actions
OEM safety interlocks on upgrading, compressor, CHP and flare packages
Hazardous-area (zone) classification and equipment selection—defined per project
Statutory approvals and certifications held by the owner, OEM or EPC
Compliance by configuration: TAS supports your reporting and audit requirements through configurable data and reports. Any certification of plant, product gas or emissions remains with the accredited bodies and responsible parties for your project.
Implementation
A phased path from assessment to lifecycle support
Start with one plant or one process area, prove the data, then scale across sites.
Site assessment
Objectives, existing systems, connectivity and stakeholder roles.
IO & protocol survey
Tag lists, OEM interfaces, analyzer outputs and meter inventory.
Integration
PLC/SCADA, edge gateway, historian and secure network design.
Dashboards & KPI validation
KPI definitions agreed and checked against field and lab data.
FAT / SAT
Factory and site acceptance testing with the owner, OEM and EPC.
Training & lifecycle
Operator training, documentation, support and multi-site roll-out.
Planning a new biogas or CBG plant—or connecting existing ones?
Talk to TAS about automation, instrumentation integration and digital operations for your anaerobic digestion, CBG / Bio-CNG, RNG or CHP project. We work with plant owners, process OEMs and EPCs from design through lifecycle support.
