A diesel engine manufacturer required specialized fuel delivery rigs to support testing with flammable fuels, such as natural gas and propane, in an engine test environment. A top priority for the client was ensuring fuel safety by creating a safe work environment for personnel, protecting valuable assets, complying with legal and regulatory requirements, and standardizing safety protocols across multiple test cells. The client also needed to ensure consistent fuel safety measures from one test cell to another.
However, the complexity of certain test cells posed additional challenges, requiring more advanced control systems, including safety PLCs to manage more sophisticated safety functions. These complex cells needed enhanced capabilities to meet the required standards. Additionally, the facility upgrades had to be completed on a strict timeline, as any delay in the project could disrupt testing schedules and impact product development timelines. Precise coordination between the client’s testing schedule and ACS’ installation process was crucial to maintain smooth operations.
ACS designed, fabricated, tested, and commissioned 23 custom fuel supply train skids specifically engineered for safe fuel delivery. Each skid included essential components such as double-block and bleed valves, pressure switches, flow meters, pressure regulators, and pressure transducers. These custom-built systems ensured that all components met the stringent fuel safety standards necessary for testing with natural gas and propane.
Beyond the fuel delivery systems, ACS also implemented facility upgrades to further enhance fuel safety across the test cells. These upgrades included a new scavenge air system, gas detection systems, and Safety Instrumented System (SIS) controls. ACS integrated safety PLCs into the SIS controls to manage the entire facility’s safety systems, ensuring that all test cells complied with the highest standards during testing operations.
For more complex test cells, ACS provided advanced safety PLCs, such as the Allen-Bradley Compact GuardLogix, which offered greater control and automation capabilities. These safety PLCs played a vital role in managing the complex safety requirements of these test cells, enabling higher levels of performance and reliability. ACS managed the installation and commissioning of the systems, ensuring that all safety protocols were in place and fully operational before testing commenced.
The outcome was a fully integrated, turnkey solution that met the manufacturer’s strict safety and operational requirements. The custom fuel delivery systems, paired with the facility upgrades and advanced safety PLCs, provided a reliable and efficient foundation for future testing with flammable fuels. This project showcased ACS’ ability to develop tailored solutions that address complex industry needs while ensuring full compliance with fuel safety regulations. The upgrades not only addressed the client’s immediate needs but also future-proofed the testing environment, allowing it to support evolving safety and technology requirements.
By successfully completing the project, ACS demonstrated its expertise in managing complex installations, meeting tight deadlines, and providing solutions that balanced technical sophistication with practical functionality. The integration of advanced control systems, including safety PLCs, ensured that the client’s test cells could operate safely and efficiently, minimizing risk while maximizing testing capacity.