Case Study · Oil & Gas / Pipeline

Hazardous Area Local Gauge Board Modernization

01 — The Project

Legacy gauge boards, rebuilt as a platform that can be maintained.

A crude oil pipeline operator ran its diesel-driven pumping and generation assets through legacy local gauge boards. Innova Technologies engineered and manufactured a series of replacement Local Gauge Board panels in bespoke IP65 / NEMA 4 enclosures.

The replacement converted gauge board functionality into a Siemens PLC platform with local HMI visibility, digital engine speed indication, start and stop controls, emergency stop facilities, RTD and thermocouple temperature monitoring, Modbus communications to the unit control panel, and structured field terminations.

Zone 2 IIB T3
Hazardous area basis
IP65 / NEMA 4
Enclosure rating
Siemens TP700
Local HMI platform
02 — The Situation

Local control the operators had to work around.

Pipeline pumping stations depend on local monitoring and control equipment that stays maintainable, stays visible to the operator, and remains suitable for hazardous-area installation. On this program the assets were Bergen 4008 diesel engine driven pumps and Allen 2006 diesel engine driven generators, running crude oil pipeline pumping and power generation duties.

The gauge boards in front of those machines were the originals.

008-situation-enclosure-open.jpg
03 — The Challenge

A legacy gauge board becomes a support risk long before it becomes a failure.

Legacy gauge board functionality creates future support risk as components, wiring practices and operator displays become harder to maintain. Replacement parts get harder to source. Undocumented wiring makes every fault take longer to trace. And a panel built to an earlier standard has to be reassessed each time the hazardous-area classification is reviewed.

04 — The Solution

We rebuilt the gauge board as a PLC platform, not a panel refresh.

Innova engineered and manufactured replacement Local Gauge Boards using bespoke IP65 / NEMA 4 enclosures, Siemens PLC hardware, local HMI displays, digital speed indication, start and stop controls, and structured RTD and thermocouple temperature monitoring.

The design incorporated hazardous-area-certified components, integrated IS I/O protection, segregated instrument wiring, documented inspection activities, customer-witnessed functional testing, and final O&M documentation.

Hazardous-area local control

Panel design for classified pipeline environments with Ex-certified devices, hazardous-area documentation and certified component selection.

Digital temperature monitoring

PLC-based RTD and thermocouple monitoring across extensive channel counts for the diesel pump and generator applications.

Local operator visibility

The front panel carries speed indication, HMI display, status indication, selector switches, start and stop controls and emergency stop.

Maintainable wiring and terminations

Structured cable ducting, segregated IS wiring, numbered terminals, clean and dirty ground bars, and labeled components support future serviceability.

Factory testing and documentation

Engineering drawings, schematic wiring, terminal diagrams, inspection records, FAT support, O&M documentation and a certification dossier.

05 — Project Specs

What was built.

Application

Local Gauge Board modernization for diesel engine assets

Operating context

Crude oil pipeline pumping and power generation duties

Equipment

Bergen 4008 diesel engine driven pumps; Allen 2006 diesel engine driven generators

Hazardous area

ATEX / Ex engineered design, Zone 2 IIB T3 with IS I/O protection

Control platform

Siemens PLC, TP700 HMI, Modbus communication to UCP

Quality

ISO 9001:2015 controlled design, manufacture, FAT and documentation

Value delivered

More Case Studies

Related projects.

Running local control panels you can no longer get parts for?

Talk to an Innova engineer about gauge board replacement, hazardous-area panel engineering and PLC-based local control for pipeline pumping and generation assets.

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FORMERLY PETROTECH

A New Name for the Company We've Become.

SAME PEOPLE.
SAME ENGINEERING EXPERTISE.
BROADENED HORIZONS.

A MESSAGE FROM JOHN KAZOUR, CEO

Welcome to Innova Technologies

To our customers and partners,

For more than 50 years, our team has helped customers keep critical operations running. We built our reputation as Petrotech by taking responsibility for control systems on important rotating machinery.

As more industries came to us with similar challenges across power generation, compression, and hydro applications, our engineering team kept finding ways to solve them. Eventually, the business outgrew the Petrotech name.

We are entering our next chapter as Innova Technologies. The new name reflects the full scope of our work as a rotating machinery control systems specialist. We engineer controls around the machine, deliver complete projects from design through commissioning, and provide support that stays with the problem until it is solved.

Our name is changing, but the people, engineering experience, and commitment behind the work continue. Our responsibility to active projects and installed systems carries forward under the Innova Technologies name. Your current contacts remain the right place to start, and we will communicate directly if an administrative record requires an update.

We appreciate the trust you have placed in us over the decades, and we look forward to continuing that work as Innova Technologies.

John Kazour

CEO, Innova Technologies