Case Studies of Projects: Innovative Solutions for Real-World Challenges
At ICS Automation Solutions, our portfolio of success stories demonstrates how we bring innovative solutions to meet real-world challenges across various industries. Dive into our case studies to explore the depth of our expertise and the impact of our work.
Transformative Overhaul of DCS Control Systems at an Oil Refinery
Challenge: An Oil Refinery was tasked with upgrading its DCS system that was struggling with obsolescence, frequent hardware issues along with recent vendor notifications that their system was nearing end of life support, increased costs for replacement parts and withering technical support. ICS was tasked with helping them to migrate their systems to a state-of-the-art DCS that is the first of its kind in Canada.
Solution: ICS Automation Solutions took on a comprehensive overhaul to rejuvenate the facility's control systems:
- Advanced HMI Upgrade: Our team rolled out an updated 800xA HMI using ABB's cutting-edge 6.1.1.2 software, configuring 27 virtual server nodes and 14 physical PCs to bolster system robustness and expand capacity.
- Efficient Database Overhaul: By leveraging ABB’s Mod300 CCF library, we significantly reduced the operational loops from 2300 to 960. This optimization cut down on commissioning time by a remarkable 4,000 hours, translating into labor cost savings of approximately $700,000 CAD, with an additional $156,000 saved on DCS system, history, and PI licenses.
- Reprogramming Critical Infrastructure: We modernized the control logic for four gas-fired boilers and updated blending programs to the more efficient Sequential Function Charting (SFC), while also ensuring all relevant documentation was thoroughly prepared for Operations, Training, and Process Control departments.
- Graphics Migration and System Testing: We modified 98 graphics to align with new system configurations and provided comprehensive operational sign-off sheets. Our use of advanced pre-commissioning testing techniques like Signal Sourcing and Analog Input function block comparison greatly minimized potential issues. This method fostered transparent communication across departments, boosting confidence in the new systems.
Results: The comprehensive system overhaul yielded significant improvements across the facility:
- Dramatic Reduction in Downtime: The new systems greatly reduced the facility's downtime and maintenance costs.
- Enhanced Operational Efficiency: With the updated systems, the facility saw improvements in efficiency, reliability, and scalability.
- Significant Cost Savings: The overhaul led to substantial reductions in both labor and licensing costs.
- Improved Operations and Documentation: The updates streamlined control logic and enhanced documentation, making daily operations more efficient.
- Smooth Transition and Startup: Through meticulous testing and the detailed PSSR, we ensured a smooth transition to the new systems, readying the facility for a seamless startup.
This overhaul not only revitalized the facility’s control systems but also set a new standard in operational excellence, proving that strategic upgrades can have a profound impact on efficiency and cost-effectiveness in the petrochemical industry.
Virtualization of ABB 800xA DSC Systems
Challenge: A petrochemical facility faced frequent downtimes and maintenance challenges due to the physical limitations and aging infrastructure of their existing ABB 800xA Aspect Systems.
Solution: ICS Automation Solutions stepped in to virtualize the client's ABB 800xA Aspect Systems. The project involved migrating physical servers to a virtualized environment optimizing the system architecture for increased reliability and scalability.
Results: The virtualization project was a resounding success, significantly reducing system downtime and maintenance costs. The client benefitted from improved system reliability, more effortless scalability, and enhanced disaster recovery capabilities. This transformational approach to system management set a new standard for the client’s operational efficiency.
Lifecycle Management of Mod300 Systems
Challenge: An established mining operation struggled with outdated Mod300 Systems, leading to inefficiencies and a lack of support for newer technologies and protocols.
Solution: Our team undertook a comprehensive lifecycle management project for the Mod300 Systems. This involved a detailed assessment of the current systems, identification of obsolescence risks, and a strategic plan for upgrades and future-proofing the systems.
Results: The lifecycle management initiative extended the operational life of the Mod300 Systems while integrating them with modern technologies. This Oil Refinery saw a notable improvement in performance, system reliability, and reduced risk of unscheduled downtimes. This proactive approach preserved the client’s investment and enhanced their competitive edge in a demanding industry.
Why Our Projects Stand Out
Each case study highlights our dedication to solving complex challenges with tailored solutions. At ICS Automation Solutions, we combine our deep technical expertise with a thorough understanding of our clients' needs, delivering results beyond expectations.
Our projects are characterized by:
Innovative Thinking
Crafting solutions that leverage the latest technologies to address specific challenges.
Commitment to Excellence
Ensuring every project is executed with the highest standards of quality and precision.
Impactful Results
Focusing on tangible benefits, including improved efficiency, reliability, and cost savings.
Connect With Us
Explore how our solutions can transform your operations. Contact us to discuss your project needs and discover how we can achieve exceptional results together. Ready to start your success story?