Within the Val d’Agri Oil Center (COVA) modernization program, Key Solution supported the ICSS upgrade and obsolescence management of a mid-1990s DCS and ESD/F&G architecture. In preparation for the 2021 shutdown, we contributed to system improvement, expansion, and reliability enhancement, ensuring continuity of operations, higher availability, and alignment with updated safety and performance standards across treatment lines and gas facilities.

Role KS

Key Solution supported the ICSS modernization strategy, covering DCS Advant Master, Safeguard ESD, 800xA supervision, and AC800M controller upgrades. We managed alarm rationalization, C&E review and optimization, safety logic testing, and ESD/DCS interface validation. Our scope included reverse engineering of legacy configurations, hierarchy definition, reset philosophy specification, system segregation for duplicated nodes, and engineering planning for hardware substitution and expansion (POS project).

Deliverables

ICSS assessment report, alarm management analysis, C&E optimization, safety logic tests, firmware upgrades, ESD expansion support, hierarchy documentation, reset philosophy definition, virtualization strategy, configuration verification tools.

Results

Improved system availability and reliability, reduced obsolescence risk, enhanced safety integrity, optimized alarm performance, and enabled a structured modernization path, ensuring stable plant operation and readiness for future upgrades.