Case Study · Refining & Process

Hydraulic Decoking Control System Modernization

01 — The Project

Decoking runs on a schedule the whole unit depends on.

A major European refinery needed a modernized control platform for its hydraulic decoking operation. Innova Technologies engineered and manufactured an integrated solution combining unit control panels, a remote operator console, HMI visualization, communications infrastructure and machinery condition monitoring.

The package brought high-availability process control, operator visibility and rotating equipment protection into one coordinated system rather than three separate ones.

Redundant
Processor and I/O architecture
Bently Nevada 3500
Machinery condition monitoring
Fiber optic
Industrial network backbone
02 — The Situation

Hydraulic decoking is unforgiving of control system downtime.

Hydraulic decoking systems operate in demanding refinery environments where system availability, operator control and machinery protection are all essential at the same time.

The existing platform limited what operators could see and made diagnostics slower than they needed to be.

006-situation-operator-console
03 — The Challenge

Availability, visibility and machinery protection, none of them tradeable against the others.

The customer required a modernized platform to improve operator visibility, increase system resilience, simplify diagnostics and support future expansion. A replacement that solved one of those at the expense of another would not have been worth doing.

04 — The Solution

Redundant control, a proper operator console, and machinery data in the same system.

Innova engineered and manufactured an integrated control solution comprising unit control panels, a remote operator console, HMI visualization, communications infrastructure and machinery monitoring integration.

The solution combined physical operator controls, touchscreen visualization, redundant process control hardware and structured field interfaces within maintainable cabinet assemblies.

High-availability control architecture

Redundant processors, distributed I/O and resilient communications infrastructure reduce single points of failure.

Industrial communications

Fiber-optic networking and industrial Ethernet support reliable communication between operator, control and field systems.

Advanced operator control and smart HMI

A dedicated remote operator console with touchscreen HMI, alarm views, permissive status, process overviews and trend screens supports operator decision-making.

Refinery-grade panel engineering

Structured wiring, labeled field interfaces, clear segregation and maintainable equipment layouts.

Machinery monitoring integration

A Bently Nevada 3500 platform integrated to support rotating equipment condition monitoring.

05 — Project Specs

What was built.

Application

Hydraulic decoking control system modernization

Operating context

Major European refinery facility

Operator interface

Remote operator console and HMI visualization

Control architecture

Redundant PLC and distributed I/O infrastructure

Communications

Industrial Ethernet and fiber-optic network architecture

Monitoring

Bently Nevada 3500 machinery condition monitoring

Value delivered

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Running a coker unit on a control platform you no longer trust?

Talk to an Innova engineer about high-availability process control, operator consoles and integrated machinery protection for refinery service.

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Open, documented, maintainable control.

IEC 61131 standardized logic your team can support without OEM lock-in.

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If your equipment runs and your downtime costs more than the controls do, let’s talk

Single-source

One team, drawing to startup.

Engineering, fabrication, installation, and commissioning under one contract.
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