Automation System Maintenance for DCS & SIS
Maintenance approach
Preventive maintenance
Ensuring continuous operation of a plant depends on the control system staying available. One of the most significant threats is a failure inside the control system. A planned maintenance strategy reduces production slowdowns and complete stoppages from DCS, ESD or historian faults.
Preventive maintenance is scheduled and interval-based: maintenance scheduling and implementation against a plan agreed with site personnel.
Condition-based maintenance
Maintenance work is targeted and condition-based: improve the efficiency, reliability and service life of your automation systems by acting on measured condition rather than on a calendar alone.
Effective maintenance starts with an audit of systems and devices. Using accurate and up-to-date condition data, we identify the actions required, when and where they apply, and eliminate unnecessary tasks.
System and device assessment supports that audit. On the refinery CHP plant we have maintained DCS, ESD, BMS and MES continuously since 2022, and for eleven years before that from 2007 to 2018.
Corrective and emergency support
Maintenance is essential for mitigating control system risk, including corrective work after a failure.
- Service calls
- On-demand support
- Emergency visit
Remote support
On-site and remote support for control systems already running in production.
Performance monitoring
- Improve process performance while reducing costs
- Minimise safety and environmental risks
- Extend the service life of installed systems
Control loop performance is monitored continuously, loops are retuned, and alternative control strategies are implemented where the existing one limits the unit.
Platforms in maintenance
- ABB Industrial IT 800xA
- Emerson Ovation
- HIMA HIQuad
- Siemens PCS7
- Siemens TIA Portal
- Yokogawa Centum VP
Performance calculation and reporting
Alongside condition-based maintenance, we implement the calculations that show whether a plant is performing as designed:
- Boiler efficiency by direct and indirect method, for gas-fired and petroleum coke fired circulating fluidized bed boilers
- Steam turbine efficiency and losses
- Thermal balances and electrical energy balances
- Process data collection from control systems and commercial metering units, with long-term archiving