Automatic Power-Outage Recovery with an Antaris Process FT-NIR Analyzer and RESULT Software

Importance of the topic

Ensuring reliable and rapid recovery of process analytical instruments after a plant power outage is essential for manufacturing continuity, process safety and data integrity. For in-line Near-Infrared (NIR) analyzers such as the Antaris FT-NIR, an automated recovery strategy minimizes downtime, provides timely process diagnostics during plant restart, and reduces manual operator intervention that can introduce delays or errors. Regulatory and security constraints in many industries also require that recovery solutions maintain controlled access and traceability.

Objectives and study overview

This technical note documents a practical, industry-ready workflow to configure an Antaris FT-NIR process analyzer with RESULT software to recover automatically after a factory power interruption. The goal is to describe the minimal system and software settings needed so that after mains power is restored the instrument and analysis software either return to a ready state or immediately resume a defined measurement workflow, enabling continuous monitoring or rapid diagnostics during plant recovery.

Methodology and configuration

The recommended recovery sequence combines simple firmware and operating-system settings with RESULT software automation features. Key steps are:

• Configure the host PC BIOS to automatically power on after AC restoration using the AC Recovery (or equivalent) setting in the Power Management section.
• If login security is required, enable a secure remote access mechanism (for example Microsoft Remote Desktop) so an authenticated user can log in remotely after reboot. Coordinate this with IT to satisfy company security policies.
• Ensure RESULT Operation launches automatically at user logon by placing a shortcut to RESULT Operation in the Windows Startup folder for the user account that will run the analyzer.
• To fully automate workflow execution, use one of two RESULT options: Industrial Automation Controls (linked to a PLC / Process Communications Controller) or OPC control. For Industrial Automation, configure RESULT’s Automation Options to map a digital PLC line (Start Workflow line number) to the desired workflow. For OPC, set the RESULT tags such as Name, WorkflowPath and RunningState so a remote OPC client can load and start a workflow programmatically.

Additional practical notes:

• When using a PLC, if a specific PLC line remains active after power return, RESULT can read this input and trigger the preselected workflow.
• Place RESULT Operation under the appropriate Windows user account used for automated operation; if a password-protected login is required, provide a secure mechanism (remote desktop or remote host) for authentication with documented IT approval.

Used Instrumentation

The equipment and software elements referenced in the setup are:

• Antaris FT-NIR process analyzer (Thermo Fisher Scientific)
• RESULT Operation software and RESULT OPC interface
• Host PC running Microsoft Windows (BIOS with AC Recovery option)
• Process Communications Controller and/or plant PLC for digital I/O integration
• Network infrastructure supporting Remote Desktop or OPC communications

Figures in the original document illustrate BIOS AC Recovery settings, Windows Remote Desktop options, copy-to-Startup steps, RESULT OPC Test Client tag fields, and the Industrial Automation Options dialog within RESULT Operation. These visuals document the locations of the settings described above and the specific tag/field names to edit.

Main results and discussion

Applying the described configuration results in two practical operational modes after a power outage:

• Ready-to-run mode: the PC powers up automatically, a permitted user can log in (locally or remotely), and RESULT Operation opens without manual startup, leaving the analyzer available for immediate use.
• Fully automated workflow mode: RESULT automatically selects and launches a predefined workflow based on PLC input or OPC tag commands, enabling unattended restart of sampling and data collection for process monitoring or diagnostics.

Key discussion points include the balance between automation and compliance. Automated restart reduces operator burden and shortens time-to-data but requires secure and auditable access controls. IT involvement is essential to ensure Remote Desktop or networked control complies with corporate security policies. Additionally, the approach depends on intact network/PLC availability after a power event; fallback to ready-to-run mode is advisable if communications are not restored.

Benefits and practical applications

Primary benefits of implementing the automated recovery workflow are:

• Reduced instrument downtime and faster availability for process control and diagnostics during plant restart.
• Lower manual intervention, reducing human error and labor demand during recovery.
• Consistent restart behavior and reliable data capture for event reconstruction and regulatory records.
• Flexible integration options: direct PLC digital input for deterministic control or OPC for remote orchestration and supervisory control.

Typical use cases include continuous manufacturing sites, quality control loops that rely on near-real-time NIR data for process adjustments, and plants where rapid diagnosis of feed or reactor conditions during restart is important for safety and yield.

Future trends and opportunities

Several developments can enhance or supersede the documented approach:

• Migration from legacy OPC to OPC UA for improved security, encryption and standardized metadata transport.
• Stronger authentication models (multi-factor authentication, certificate-based machine identities) for automated logon and operations while preserving audit trails.
• Containerized or service-based analytics that allow software to restart independently from a single PC image, improving maintainability and version control.
• Integration with plant-wide orchestration and digital-twin platforms to coordinate analyzer startup with other process equipment and data historians.
• Deployment of resilient hardware architectures (redundant power supplies, UPS, watchdog controllers) to reduce the frequency of hard outages and ensure safe shutdown/restart behavior.

Conclusion

Configuring BIOS AC recovery, enabling controlled remote login, autostarting RESULT Operation, and using RESULT’s Industrial Automation or OPC interfaces enables an Antaris FT-NIR analyzer to recover automatically after a power outage. This approach supports either quick availability in a ready state or immediate resumption of predefined measurement workflows, helping plants regain analytical capability rapidly while maintaining options for secure operator control and regulatory compliance.

Reference

Jeffrey Hirsch. Automatic Power-Outage Recovery with an Antaris Process FT-NIR Analyzer and RESULT Software. Thermo Fisher Scientific, Technical Note TN51262, 2006.