Technical service
for safe and efficient
system operation

Commissioning, Modernization, trouble
shooting and maintenance – worldwide and
cross-system

Reliable operation starts with right system support

Our service ensures stable and secure operation of complex automation systems throughout the entire plant lifecycle.

In cooperation with our partners in field of mechanical and plant engineering as well as construction, we ensure automation solutions that remain manageable, reliable and auditable.

This way we reduce the risk of failure or shutdowns, secure your investments and enable consistently high plant performance.

High plant availability though solid and field-proven maintenance strategies

Minimizing technical risks by specific system and batch-service checks

Safety inspections with focus on process integrity, functional safety (e.g. SIL3) and cybersecurity

Integration of modern control and monitoring technology

Unified service approach across systems and vendors

How service creates real value

Every industrial plant has unique requirements. Therefore, we tailor our services precisely according to these needs. Based on actual operating conditions our services are designed to improve plant availability, reliability, safety and maintainability.

Modernizing automation solution for two turbo compressors

As part of an expansion and modernization for the compressor station of a natural gas storage facility, together with the machine manufacturer, two turbo compressor control systems have been modernized, replaced and successfully recommissioned.

  • Delivery of a dedicated PCS7 control system per each compressor
  • Delivery and installation of prefabricated mounting plates
  • Implementation of a safety-related SIL2 shutdown
  • Anti-surge control modernization
  • Commissioning of the entire automation system

Spare part package

In cooperation with the OEM, AviComp is permanently monitoring the automation systems for multiple compressor trains in a chemical plant complex. Spare part inventory, availability as well as the risk of errors and downtime are continuously assessed. If necessary, we supply and configure spare parts and support the integration process.

  • Objective: Ensuring a high plant availability in the long term
  • Annual evaluation of a redundant S7-400 system
  • Including all associated peripheral, communication, and system components
  • Evaluation of criticality, delivery time, interchangeability, and probability of failure
  • If necessary, procurement and parameterization of components for rapid replacement
  • Support for spare parts integration

Commissioning of the automation systems for a compressor station

For a new compressor station in an ammonia production facility, we carried out the commissioning for the Control and monitoring systems. The scope of services included loop checks, on-site tests, support for trial operation and test runs, as well as training for the operators and maintenance personnel.

  • Automation Solution based on Siemens PCS7 and redundant S-400H Control System
  • Implementation of a Bently Orbit60 MMS, safety function and DCS integration
  • Setting up a remote communication for commissioning and maintenance purposes
  • Commissioning of UCP and MCC as well as LCPs and JBs installed in the hazardous area (Ex)
  • Consideration of process- and machine-specific characteristics
  • Training for operators and maintenance personnel

Migrating the automation system for a Combined Heat and Power Station (CHP)

Control logic migration for three natural gas compressors from a SIMATIC S5 to the a modern and advanced ABB control system. The existing algorithms and the control philosophy hast been analyzed, verified and optimized supported by the new state-of-the-art hardware and software technologies.

  • The result of the migration is a future-proof and high-performance control solution that ensures a long-term and reliable plant operation
  • The implementation of a master control system also took the environmental and energy efficiency aspects into account

Service with process know-how and system insight

Reliable service for automation systems does not result from individual measures, but from deep system understanding and a methodical approach.

Our Services combine in-depth expertise in control and monitoring systems, control philosophies, process controls (e.g. DCS) and field instrumentation – complemented by our extensive know-how for plants and their processes.

In terms of service, this means for us: mastering technical complexity, making risks transparent, and implementing measures in a way that plant operation and investment protection are guaranteed long term.

System-oriented approach: automation, control, protection systems, and instrumentation as an integrated overall system.

Systematic engineering: structured technical evaluation of complex interactions as a basis for decision-making.

Transparent risk assessment: clear identification, evaluation, and documentation of technical risks.

Traceability throughout the life cycle: Technically justified measures with consistent documentation for operations and audits.

Our Services for automation solutions

Our service portfolio includes dedicated services for the operation, the subsequent development and the long-term security of your automation systems.

Our technicians and engineers have tested and commissioned over 1,500 systems worldwide. Their focus is hereby on a safe and efficient transition from start up to plant operation.

  • System, function and integration tests for automation solutions
    Loop and signal checks
  • Commissioning control, monitoring, safety and protection systems
  • Support for the integration of machinery and package unit controls into the DCS
  • Testing of protective and safety functions
  • Fine-tuning of control structures and parameters during plant operation
  • Virtual commissioning and testing to minimize risks before commissioning on site
  • Training for operators and maintenance personnel

We provide operating companies and service organizations with structured analysis of malfunctions and deviations cause by automation systems – with a focus on sustainable root-cause analysis (RCA).

  •  Analysis of control and safety functions
  • Online diagnostics as well as trend and operating data analysis
  • Root-cause analysis (RCA) for recurring plant malfunctions
  • Differentiation between control, automation and process root causes
  • Support through model-based analyses and simulation for complex process conditions

We manage re-engineering and migration projects to replace obsolete technology and securely transfer automation systems to modern hardware and software platforms.

  • Analysis of existing control and automation architecture
  • Migration to state-of-the-art system platforms for different automation system suppliers
  • Retrofitting and modification of control and safety functions
  • Integration of existing machinery and package unit controls into modern distributed control systems (DCS)
  • Securing a seamless system migration through virtual commissioning and testing

We lead the modernization of existing automation systems in close cooperation with our customers‘ service organizations – with the aim of ensuring the reliability, energy efficiency and future viability of machine and system.

  • Evaluation of existing systems and inventory
  • Development of modernization and migration concepts
  • Planning and supervision of start-up and shutdown processes
  • Delivery and integration of new automation systems
  • Risk-free optimization of the existing control philosophy and parameters by dynamic simulation and Digital Twin support

We support operator companies as well as machinery and plant manufacturers by ensuring a secure supply of spare parts and dealing with obsolete and discontinued components.

  • Creation of project-specific spare parts lists
  • Delivery of suitable spare parts for the installed systems
  • Support for discontinued products and provision of alternative solutions
  • Replacement of components including modification, conversion and rewiring
  • On-site service or remote support for the exchange and integration of spare parts

We support the ongoing plant operation with technical and operational support, on-site or remotely – to ensure reliability and plant safety.

  • Technical support for issues related to plat operation and malfunctions
  • Remote support via secure communication (e.g. VPN)
  • Access to control panels, controllers and process data for diagnostics
  • Support for software and logic changes, updates and parameter settings
  • Training for operators and maintenance personnel

Find out more or discuss your specific application?

 

Volker Morgenstern
Technical & Product Support

 
Phone: +49 341 21787-1740
Mobile: +49 1525 6858240
Email: volker.morgenstern@avicomp.com
Teams: vmorgenstern@avicomp-le.com