Ensuring 99.4% Uptime: How Tri Tech Automation Delivered a High-Reliability Gas Pipeline Solution

The Situation

In the world of natural gas transmission, uptime isn’t just important – it’s everything. For a major greenfield gas line, ensuring continuous gas flow to its destination meant designing a robust and intelligent system that could meet the stringent requirement of 99.4% uptime. With only four hours of allowable downtime per year and the risk of incurring hundreds of thousands of dollars in fines per day for service disruptions, they needed a partner with the expertise to deliver an innovative and fail-safe solution.

The customer had two compressor stations on the 42” pipeline, with the line being expanded in 2022. Both stations were primarily unmanned, with remote access from the main office. In the operating area, their systems were a hodge-podge of different programs, many of them outdated. Each site had a networking panel, a main control panel, two remote IO panels, and a motor control center – but these two sites were not linked to each other on a larger network; each site was independently managed and run. All site operators had access to the control monitor, where some diagnostics could be done. However, most of the troubleshooting required a technician to drive all the way out to the compressor station to access the PLC just to determine what the problem was (and then hopefully be able to fix it).

The Customer’s Need

The pipeline expansion project was no ordinary task. The customer needed to expand their existing system, integrating new infrastructure while maintaining high levels of reliability. In the original pipeline, both points ran east to west, and gas was only running east; one was pulled to go south, and the other east to west. All of this required a solution that could not only achieve an unusually high uptime of 99.4%, but also enable bi-directional gas flow to maximize operational flexibility, overcome supply chain disruptions due to Covid, and be deployed within one year – an aggressive timeline given the complexity of the project.

The customer was already behind at the start of the project due to Covid delays, and they were contractually required to deliver a set amount of liquified natural gas (LNG) per day or else face steep daily fines. Their one-year timeline was already aggressive, and they would need ongoing maintenance as well. They had to make sure that at a minimum they could meet the needs to the south creating a system that could flow north to south as well as west to east. On top of this, with compressor station sites 90 miles apart, the customer needed one standardized, remote solution that would improve and streamline operations at both facilities.

The Tri Tech Solution

Tri Tech Automation had worked with this customer before on other pipeline projects, so we were ready to jump in and tackle their new expansion. Our team got to work designing a solution that covered everything—electrical systems, power control, network setup, and final testing. “When we start a project, we like to sit down with the customer, map out ideas on a whiteboard, and walk them through our design concepts to show how we’ll make the system reliable,” said James Maisel, VP of Strategic Initiatives. Tri Tech focused on developing a strong, dependable system that made life easier for both technicians and operators. After creating detailed engineering and design plans, we refined everything to match the customer’s exact needs, making sure the final solution was a perfect fit.

One major advantage Tri Tech offered was the ability to fully assemble and test the entire system right in our warehouse before installation. This gave the customer a hands-on preview of how everything would operate in a real-world setting. Even better, we connected it directly to their actual network, so they could see firsthand how everything functioned in a controlled environment before deployment. Once the setup was live, we put it through its paces—running stress tests, checking the backup power systems (UPS and generator), and simulating operations for both locations from one central spot. One of the biggest wins? We proved that even if certain devices were shut down or the entire system was unplugged, it would keep running smoothly, thanks to built-in fail-safes. This gave the customer total confidence that the network would perform reliably on-site. We also tackled the programming side, making sure all components worked together seamlessly and keeping the customer involved every step of the way to ensure it met their expectations. In the end, we designed a network and control strategy that hit the contract’s 99.4% uptime requirement—ensuring a rock-solid, dependable system.

Because the compressor stations were largely unmanned, Tri Tech’s solution ensured maximum operational efficiency with minimal on-site staff intervention. Operators would be able to diagnose and resolve many issues remotely without needing a technician, and the high redundancy of the system would allow uninterrupted gas flow, even in case of component failure. Additionally, Tri Tech focused on making system operation more accessible and efficient by bringing a uniform system design across both compressor stations, and tablets where they could manage and monitor processes allowing for easier troubleshooting and maintenance. Operators liked this new touch-screen interface so much, they began requesting tablet-based HMIs in the field, giving them mobile access to system controls and reducing the need to walk back and forth to and from centralized control panels.

The Results

Tri Tech successfully delivered the project on time, even with supply chain challenges and a tight schedule. With COVID-related uncertainties adding pressure, our decision to stock up on key materials ahead of time made all the difference. By using advanced PlantPAx control systems, a strong backup network, and smart project planning, we helped the customer not only meet their contractual requirements but also raise the bar for efficiency. They were thrilled with the system’s performance and features, and their operators and I&E specialists appreciated the streamlined, standardized setup. Senior Controls Engineer Steve McNamer explained: “On some systems, if you hit start and nothing happens, a tech has to dig into the PLC to figure it out. Now, operators can see exactly what’s going on right from the interface.”

The positive outcomes for the customer included:

Zero service interruptions, avoiding costly fines.
Enhanced operator efficiency with remote diagnostics and mobile access.
A new, user-friendly ISA-101.01 HMI design with easy-to-see alarms and alerts.
Uniformity and efficiencies in troubleshooting, with physical and technical hardware now identical at both locations.
A bi-directional strategy that allows gas to flow both east to west and north to south out of one station, while addressing surge issues on the line.
Improved system reliability and uptime, ensuring seamless gas delivery.
A satisfied customer with minimal support calls – proof that the system was functioning as flawlessly as intended.

The success of this project has strengthened Tri Tech’s relationship with the customer, solidifying our position as a trusted partner for future high-stakes infrastructure projects.