P-S’s automation system staging and integration services are among the most comprehensive and experienced in the Houston area.  Our 17,000 square foot staging facility enables us to design, assemble, integrate and test basic process control systems (BPCS) integrated with safety systems, fire and gas systems, digital bus networks, vibration monitoring systems, PLC’s, analyzers systems and/or a myriad of serial-communicating  devices. 

Hardware Staging

Our Project Managers, which have an average of over 17 years of automation experience, direct this facility. They manage the design and assembly of systems ranging from simple sub pans to 60’ x 18’ automation enclosures.  We provide complete system enclosure drawing packages for review and approval.  Our staging assembly team builds the systems per the project’s custom design.  Often the entire control network is staged including serial, OPC and digital bus connections.  Once the system is assembled and pre-tested, our project managers and assembly team are ready to conduct the customer-specified hardware acceptance test.  This can be accomplished with I/O software simulation and/or signal generating test equipment.

System Configuration and Hardware Integration

Puffer-Sweiven’s Control Systems (CS) Specialists have an average of over seventeen years of process control and automation experience in the chemicals, petrochemicals, refining, and power industries.  Their unit operations expertise covers batch and continuous reactors, distillation, fluidized beds, boiler/furnace controls and utilities, sequencing, material handling, tankage and custody transfer. 

Our CS Specialists can manage all phases of a BPCS software application design and control strategy implementation.  Our system of standards implementation and comprehensive configuration testing minimizes projects costs by reducing onsite commissioning time.  Utilizing project-specific design document that defines configuration requirements and standards, a team of CS Specialists implement and pre-test configuration.  This team may consist of operating company, EPC contractors and Puffer-Sweiven personnel. 

Configuration acceptance testing is accomplished using I/O simulation software, hardwired devices and/or digital bus devices.  All BPCS devices and ancillary systems may also be tested.  Typically I/O signals are verified from system I/O channels on the cards through the operator consoles

Operator Orientation

Using the tested system configuration, operator orientation to the new console environment can commence.  CS Specialists can provide operators with process animation to emulate simple system dynamics with the same application used for acceptance testing.  Our inexpensive techniques and tools give operators the required knowledge to use their new console effectively. The Lead CS Specialist and the Operations representatives jointly identify the training content and goals.  This is not first principles modeling but is sufficient to illustrate to operators the new BPCS console’s functionality.  This is usually taught by the Lead Control Specialist with assistance from Operations.

Onsite Installation

Concurrent with operator training, system installation and site acceptance can commence.  Depending on our scope, the Project Manager will oversee removal of an existing system, installation of all new systems, re-termination of field wiring at marshalling racks, loop check, installation of  the control network,  BPCS initialization and troubleshooting, site acceptance testing and unit start up.  These tasks can be accomplished using plant, Puffer-Sweiven and/or contract personnel. 

Custom Fabricated Enclosures

SCADA Controller and Solar Panel

Remote Enclosure for DeltaV, Shutdown, and Vibration Monitoring