Serving the Processing Industry
Our services are utilized in continuous and batch manufacturing applications across many industries. We provide solutions for most of the prominent control systems and several operational data management systems.
Project Examples
US BASED MIDSTREAM PETROLEUM COMPANY – TEXAS
Gas Processing Migration and Upgrade Project
Provided design, implementation, and startup of Gas Processing Facility. Multiple individual automation systems, including Delta-V, TI-505, Wonderware and other PLC platforms, were reverse engineered and control logic migrated to the Foxboro EVO Control Platform and the Triconex Safety System to provide a centralized and unified interface. Project included full I&E design package, including loop diagrams and support for new control building, and round the clock commissioning and startup support to ensure successful execution within the turnaround window.
MAJOR US BASED ENGINEERING COMPANY – TEXAS
Refineries Modernization Program
SAS was contracted by major EPC to be their subject matter expert for Foxboro DCS upgrade program. SAS assisted in determining the current state of the systems and developing the requirements to upgrade the systems to Schneider Electric’s current offering.
US BASED PETROLEUM CORPORATION – ALASKA
Multiple Analyzer Remote IO Panels
Programmed, fabricated, and installed EcoStruxure Foxboro DCS remote IO panels for analyzer interfacing on multiple projects. SAS was able to adapt and customize factory-available, OEM panels to client requirements, rather than fabricating from scratch, reducing the time and cost to the client. SAS interfaced with client and third-party contractors for successful implementation and provided on-site commissioning support.
WATER / WASTEWATER UTILITY – TEXAS
Modicon PLCs and Wonderware SCADA Project
Replacement of 8 existing Allen Bradley SLC500 PLCs with new Modicon M340 PLCs using Modicon’s quick wiring adapters. The quick wiring adapters allowed SAS to replace the PLCs in 2-3 hours each without touching any field wiring. This allowed for no plant downtime as the equipment that was being controlled by the PLC being replaced was operated manually while the PLC was being replaced. The new Modicon PLCs communicate with the Wonderware SCADA via Ubiquiti airMAX AC radios.
US BASED MIDSTREAM PETROLEUM COMPANY – LOUISIANA
Amine Train Project
Provided project and control system support for the relocation of customer’s Amine Train. From disassembly to commissioning and startup at the new asset location, SAS provided complete support through the entire process. This included adding the relocated Train to the existing Allen Bradley control system and updating the existing ClearSCADA application to include a second Train.
US BASED MIDSTREAM PETROLEUM COMPANY – LOUISIANA
IFM Upgrade Project
In-place upgrade of 60+ Allen Bradley IFMs to terminal block configuration to eliminate IFM faults that were causing process upsets. Project also included the installation of 24VDC UPS backups in each RIO to provide secondary backup to the facility backup generation. All onsite panel modifications, wire terminations and loops checks were completed by SAS. Process uptime has substantially improved as a result.
Global Chemical Company – Freeport, TX
DCS Interlock Validation Foxboro IA
Back documentation of online DCS interlocks and comparison to offline Cause & Effects.
Scope of DCS Interlock documentation included over 9,400 control blocks.
Tank Storage Company – Port of Houston TX
GE PLCs & DeltaV
Development of control narratives that described the functionality of all existing site GE PLCs (Fanuc 90 & 30 series) used to control and provide safety interlock logic associated with all shipping docks, truck racks, and flare/vapor recovery systems used for the loading and unloading of stored chemical products.
The control narratives are to be used to configure a new Delta V DCS to replace the obsolete GE PLCs.
Water Utility – Texas
SCADA and PLC Water Projects
Numerous projects using Modicon M340 and M580 PLCs, Wonderware SCADA, Peplink cellular routers and Ubiquiti airMAX ac radios supporting this large industrial, agricultural and municipal water supplier. Designed, built, programmed and commissioned PLC control panels for several different type of potable water distribution systems including automatic control of in-line booster pumps to maintain minimum flow and pressure on a major potable water distribution line and several flow and pressure metering stations for several municipal customers. Set up automated gate control to maintain constant canal level at one key site and automated gate control to provide automatic flow control out of 2 different supply reservoirs.
Major Municipality – Texas
Wastewater Treatment Plant
Replaced 3 existing GE 90-30 PLCs and Genius I/O with new Allen Bradley CompactLogix PLCs and developed a new Wonderware SCADA system. Designed, built, programmed and commissioned 1 new PLC and 2 new remote I/O (RIO) cabinets, retrofitted PLCs into 2 other existing PLC cabinets and retrofitted RIO into 2 other existing cabinets. The entire system communicates via a Ubiquiti airMAX ac radio system. All equipment was installed and commissioned with no plant downtime.
US Based Midstream Petroleum Company
Permian Basin Plant Support
Project-specific and ongoing on-site support and implementation of multiple third party interfaces and DCS controls for multiple plants in the Permian basin.
Renewable and Advanced Biofuels Provider in N.A.
IA Series Upgrade
IA Series upgrade from InFusion 1.0 to FCS 6.0.
US Based Petroleum Company
Advanced Regulatory Controls
Advanced Distillation Overhead Controls, Advanced Level Control Algorithm, Heater Cross-Limiting Combustion Control, Heater Pass Outlet Temperature Balance, Crude Unit Preflash Drum Level Control.
Major US Refiner
DCS Based Advanced Compressor Controls
Implemented Foxboro DCS‐based compressor controls for four Sulfur Plant combustion air, FCC Wet Gas, Hydrocracker Recycle, and Coker Wet Gas compressors
Biofuels Alternative Fuels Company in Gulf Coast
Control System Design & Configuration
Performed all DCS project functions including system design, implementation, and on-site commissioning and start-up. Conversion of AB PLC controls to IA Series DCS, expansion of an additional train, Alarm Rationalization.
Major Chemicals Producer Located in Gulf Coast
Configuration and SIS Integration
Developed database and initial control configuration for 3000+ I/O point DCS. Implemented interface to two Triconex shutdown systems and A-B PLCs to provide and integrated solution.
Major N.A. Refiner
Oil Movement Systems
Specified, Implemented and Supported numerous Oil Movement Systems over a multi-year period.
Major Food Producer – US
Control System Design - Elimination of Rework
Reviewed production problems and analyzed existing controls systems and practices. Specified changes to control systems to eliminate significant rework. Designed and implemented human interface for three projects. Developed application to generate interlock logic displays based on control configuration data. Developed functional cross-reference utility to assist plan engineering in trouble shooting. Provided interactive HTML-based documentation of client standards.
International Oil Company
Lube Blending Facility Controls and Information Management
Analyzed work processes, existing controls, and data management systems at two independent lubes facilities. Specified system upgrade plans to meet new business objectives.
Major Municipality – Tennessee
New PLC based SCADA System
A $1.8M Public Utilities project for supply of new SCADA system to monitor the water and gas distribution systems, and waste water collection system. Provided professional services for project management, system design & engineering, procurement, system integration, installation and startup.
Food Manufacturer – Gulf Coast
SPECTRUM Migration
Provided Spectrum Migration, and SMS and HLBL Sequence Consulting. Developed application to replicate control and display databases for the first train to the sister trains, greatly reducing the implementation time.
Gas Producer – Texas
Moore APAC Migration
Migrated control logic from Moore APAC system to I/A Series system, saving significant cost and time in database development. Implemented logic for reactor, configured regulatory and advanced controls and human interface. Provided on-site commissioning and start-up support.
Chemicals Manufacturer Located in Gulf Coast
DCS HMI Design and Configuration
Designed and implemented human interface for three projects. Developed application to generate interlock logic displays based on control configuration data. Developed functional cross-reference utility to assist plan engineering in trouble shooting. Provided interactive HTML-based documentation of client standards.
Major Food Producer – US
Control System Design - Elimination of Rework
Reviewed production problems and analyzed existing controls systems and practices. Specified changes to control systems to eliminate significant rework. Designed and implemented human interface for three projects. Developed application to generate interlock logic displays based on control configuration data. Developed functional cross-reference utility to assist plan engineering in trouble shooting. Provided interactive HTML-based documentation of client standards.
US Based Refiner
SPECTRUM System Migration
Performed all project functions including control configuration and human interface for VideoSpec, UCM, and UIO migration. Provided on-site cutover and start-up support.
US Based Midstream Oil Company
PROVOX Migration Regulatory and Advanced Controls Design and Configuration
Migration of Provox Series 10 to IA Series system. Assisted in the design and implementation of regulatory and advanced control logic. Designed and implemented Modbus interface to Optrol computer, and GE-9070 PLCs. Designed and implemented interface to applied automation GC unit. Configured OPC interface to plant’s measurement LAN.
US Based Power Generation Company
SPECTRUM System Migration
Provided migration consulting and implementation of UCM, FIO, and SMS Spectrum system components, including re-implementation of Spectrum Multi Station tasks and reporting functions. Implemented custom interface to field RTUs via telemetry system.
Venezuelan Based Oil Company
SPECTRUM System Migration
Provided database and control configuration for the migration and translation of UCM, FIO, and SMS Spectrum system components to a new DCS. Controls included anti-surge control of two trains of eight compressors.
International Oil Company (upstream)
Alarm Management
Designed and implemented alarm management system. Provided alarm rationalization and alarm management philosophy for 10,000 point FPSO to provide improved alarm monitoring and operator response.
Supplier of Alarm Analysis Tools
Alarm Analysis Tools Integration to IA Series DCS
Provided application development consulting support to third party supplier of alarm analysis tools to integrate their software with the I/A Series control system. Provided alarm and configuration extraction application.
Chemical Manufacturer – US East Coast
HMI, Alarm Management, Data Acquisition
Provided on-site support, including third party device integration and human interface design, for 2000+ point A-B interface. Automated the configuration of controls and human interface databases, and developed application to replicate reactors, leading to shorter project schedule. Implemented custom alarm manager scheme to improve operator effectiveness.
Venezuelan Based Oil Company
SPEC200 Migration
Assisted in developing design philosophy for migrating existing SPEC200 controls into the I/A system. Provided control philosophy, database support and human interface design consulting.
Chemical Company located in Gulf Coast
Batch Control System Design and Implementation
Played a major role in the design and configuration of regulatory and advanced control strategies. Implemented HLBL batch logic and human interface. Migrated HLBL batch logic taken from sister unit in Germany, which saved significant time in database development.
Gas Producer – Middle East
Device Integration with DCS
Designed and implemented gateways linking IA Series system to A-B network, and Bristol-Babcock RTU network containing 50+ RTU units via telemetry and fiber networks. Designed and implemented Visual Basic reporting package.
Gas Producer with Facilities in Texas and Oklahoma
Control System Design & Configuration
Provided on-site support including control configuration and human interface consulting. Automated configuration of control and human interface databases, saving significant time on project and eliminating data entry errors.
Gulf Coast Refiner
Oil Movements and Storage Systems
Played a key role in the design of a standard inventory management solution for major refiner, which is utilized across their fleet of refineries. Project managed initial rollout of the standard corporate solution.
Global Marine Storage Terminal Company
Inventory Management Systems Upgrade
Provided front end engineering and design services. Reviewed existing work processes and support systems. Specified new systems to upgrade existing infrastructure in support of new work processes.
Gulf Coast LNG Terminal
TDC2000/3000 LNG Gasification System Migration and Expansion
Migrated TDC2000/3000 systems to IA Series system. Assisted in design, implementation, and commissioning of control philosophy. Implemented interfaces to tank gauging, skid compressor, RTU, analyzers, BMS PLCs and plant business reporting applications.
Grassroots Chemicals Terminal in Louisiana
Control and Inventory Management Systems
Assisted in the specification and design of grassroots chemicals storage facility. Facility included dock, railcar, truck and drumming systems. Solution included inventory management systems with interface to in-house accounting system. Provided startup support of delivered system.
Major Municipality – Texas
Flood Control System
Configured all regulatory control and flood control logic for flood diversion tunnel. System prevents flooding of the city by diverting flood waters beneath the city. Provided on-site commissioning and start-up support. Implemented modified Nodebus via ISDN technologies to support widely distributed system architecture.
Major Municipality – Missouri
Water Reclamation Data Acquisition
Designed and implemented 10,000+ soft point system via OPC Interface to existing drainage and lift station iFix-based SCADA system to provide unified plant and SCADA operations. Unix/Windows-based System.
Major Municipality – Arizona
Water Reclamation Facility Expansion
Performed all project functions including control configuration and human interface for 1500 I/O point expansion project. Provided interactive HTML-based documentation package. Unix-based System.
Major Municipality – Nevada
Water Reclamation Facility
Performed all project functions including regulatory control, advanced control, and human interface configuration. System design included Wonderware SCADAlarm alarm notification, and Hardware Alarm Dialer system to alert the operator of problems. Provided on-site commissioning and start-up support. Implemented custom alarm manager scheme to enhance operator effectiveness. Provided interactive HTML-based documentation package.
Major Municipality – Georgia
Environmental Reporting
Implemented custom Production and EPA reports. Reports are executed from the central office via the city’s WAN, and generated from remote I/A nodes. Unix-based System.
Major Municipality – Tennessee
PLC Migration Water Reclamation Facility
Implemented distributed interface to DeviceNet via FDSI interface. Migrated control logic from Steeplechase VLC and Citect HMI to reduce the time required to develop the system database.
San Juan Chemicals Manufacturer
Controls Systems and EPA Pharmaceutical Reporting
Worked on-site to develop Sequential Function Chart and provide control configuration commissioning, start-up, and EPA regulation testing support. Implemented configuration extraction reports to aid plant maintenance staff. Unix-based System.