HL Engineering Services
Request Consultation

Turbomachinery Control Solutions for Critical Industries

HL Engineering Services delivers specialized turbomachinery control solutions backed by decades of industry expertise. Our engineering team provides innovative yet practical approaches for Oil & Gas, Petrochemical, and Power Generation facilities.

About HL Engineering Services

HL Engineering Services, LLC stands at the forefront of turbomachinery control solutions, delivering specialized consulting services to the Oil & Gas, Petrochemical, and Power Generation industries. Our firm combines deep technical knowledge with practical field experience to address complex engineering challenges.

What sets us apart is our team of highly skilled engineers who bring decades of hands-on experience to every project. We pride ourselves on developing solutions that are both innovative and practical—cutting-edge in their approach yet grounded in real-world effectiveness.

Our comprehensive service portfolio spans the entire lifecycle of turbomachinery control systems, from initial Residual Life Assessment through Conceptual Design to Implementation and After-market Monitoring services. This end-to-end capability ensures seamless project execution and long-term system reliability.

At HL Engineering, we're committed to delivering cost-effective, reliable, and efficient solutions that align perfectly with our clients' objectives and exceed industry standards.

Our engineering team combines theoretical expertise with practical field experience to deliver optimal solutions for your turbomachinery challenges.

Core Services: Turbomachinery Control System Engineering

System Requirements & Architecture

We develop comprehensive functional requirements, control philosophies, and system architectures tailored to your specific operational needs. Our approach balances technical performance with practical implementation considerations to ensure optimal system design.

Engineering & Procurement Specifications

Our detailed engineering and procurement specifications ensure all system components meet the highest quality standards while maintaining compatibility with existing infrastructure. We develop documentation that facilitates accurate vendor quotations and streamlines the procurement process.

Control System Design Validation

Our rigorous electrical design validation process identifies potential issues before implementation, reducing commissioning time and preventing costly field modifications. We apply industry best practices and leverage our extensive field experience to ensure robust, reliable system performance.

PLC/PAC Implementation

We specialize in implementing PLC/PAC software solutions using structured programming methodologies that enhance maintainability and troubleshooting capabilities. Our implementation includes comprehensive testing protocols to verify functionality across all operational scenarios.

Factory Acceptance Testing

Our engineers coordinate and oversee Factory Acceptance Tests (FAT) to ensure all systems meet design specifications before shipment. This critical step validates system performance and minimizes issues during site installation and commissioning.

Site Installation & Commissioning

We provide expert supervision during installation, commissioning, and startup phases to ensure smooth system implementation. Our field engineers work closely with site personnel to address any challenges that arise during these critical phases.

System Interfaces & Integration

Seamless integration between control systems and broader plant infrastructure is essential for operational efficiency. Our interface solutions bridge the gap between turbomachinery controls and your existing systems.

HMI/SCADA System Design

We develop intuitive, operator-focused HMI/SCADA systems that present critical information clearly while allowing for efficient control of turbomachinery assets. Our designs follow human factors engineering principles to reduce operator fatigue and minimize error potential.

Feasibility Studies

Before undertaking integration projects, we conduct thorough feasibility studies to identify technical constraints and opportunities for seamless connectivity between new turbomachinery controls and existing plant systems. This approach minimizes implementation risks and optimizes system performance.

Engineering Workstation Setup

We establish robust engineering workstations and maintenance tools that empower your technical team to monitor, troubleshoot, and optimize system performance. Our solutions include appropriate security measures while maintaining accessibility for authorized personnel.

Each interface solution we develop incorporates cybersecurity best practices and follows a standardized approach to documentation, ensuring that your technical teams can efficiently maintain and modify systems as operational requirements evolve.

Specialized Training Programs

Knowledge transfer is a critical component of successful turbomachinery control implementations. HL Engineering Services develops and delivers customized training programs that address the specific needs of your technical personnel.

Our training philosophy focuses on practical knowledge that empowers your team to confidently operate, maintain, and troubleshoot control systems. Rather than generic, one-size-fits-all approaches, we tailor each training program to address the specific equipment, applications, and platforms deployed at your facility.

Our training programs typically address three key audiences:

  • Operators - Focus on normal operation, alarm response, and basic troubleshooting procedures
  • Maintenance Personnel - In-depth coverage of hardware components, preventive maintenance, and fault diagnosis
  • Engineers - Advanced topics including control strategy, software modification, and system optimization

Training can be delivered on-site at your facility, allowing for hands-on interaction with actual equipment, or at our training center where we maintain demonstration systems for various control platforms.

"The customized training provided by HL Engineering was exceptionally valuable. Their instructors combined theoretical knowledge with practical examples that directly applied to our specific equipment configuration. This approach significantly reduced our learning curve and improved our maintenance team's troubleshooting capabilities."

— Operations Manager, Major Gulf Coast Refinery

On-Site Engineering Services

Failure Analysis

When unexpected failures occur, our engineers conduct thorough investigations to identify root causes and implement corrective measures. We analyze both mechanical and control system aspects to develop comprehensive solutions that prevent recurrence.

  • Root cause determination
  • Sequence of events analysis
  • Corrective action development

Residual Life Assessment

Our systematic approach to evaluating existing control systems identifies components approaching obsolescence and assesses the overall health of your turbomachinery controls. These assessments provide the foundation for strategic upgrade planning.

  • Component lifecycle analysis
  • Obsolescence risk evaluation
  • Phased upgrade planning

Technical Advisory

Our experienced engineers provide objective, vendor-neutral guidance on turbomachinery control issues. Whether evaluating proposed modifications or troubleshooting persistent problems, we offer practical advice based on decades of field experience.

  • Site audits and evaluations
  • Technical specification review
  • Implementation strategy development

Remote Monitoring Services

Our remote monitoring services leverage secure connections to your turbomachinery control systems, allowing our specialists to provide ongoing support without the need for constant on-site presence. This approach enables:

Proactive Issue Identification

By analyzing performance trends and system behavior, we can identify potential problems before they lead to equipment trips or failures.

Rapid Response Support

When issues do occur, our engineers can quickly access system data to expedite troubleshooting and provide targeted guidance to your on-site personnel.

Performance Optimization

Continuous monitoring allows for identification of optimization opportunities that can improve efficiency, extend equipment life, and reduce operating costs.

Control & Automation Platform Expertise

HL Engineering Services maintains deep expertise across all major industrial control platforms used in turbomachinery applications. This versatility allows us to work seamlessly with your existing infrastructure or recommend optimal platforms for new implementations.

Rockwell Automation/Allen Bradley

Our engineers hold advanced certifications in Rockwell Automation technologies and have implemented numerous turbomachinery control solutions using ControlLogix and CompactLogix platforms. We leverage the strengths of these systems, particularly their robust communication capabilities and tight integration with motor control centers.

Siemens

With extensive experience in Simatic S7 and TIA Portal environments, our team has successfully deployed Siemens-based solutions for critical turbomachinery applications worldwide. We're particularly skilled at optimizing these systems for high-availability applications where redundancy and fault tolerance are essential.

GE Intelligent Platforms

Our expertise with GE's Series 90, Rx3i, and Rx7i platforms enables us to support both legacy systems and implement new solutions using these reliable controllers. We've developed specialized function blocks for turbomachinery applications that enhance the performance of these platforms.

Our Platform Selection Philosophy

When recommending control platforms for new implementations, we consider several critical factors:

  • Existing Infrastructure - Leveraging your installed base can reduce training requirements and spare parts inventory
  • Application Requirements - Matching platform capabilities to the specific demands of your turbomachinery application
  • Long-term Supportability - Evaluating vendor commitment to platform longevity and migration paths
  • Performance Characteristics - Scan times, communication capabilities, and redundancy features
  • Total Cost of Ownership - Looking beyond initial purchase price to consider lifecycle costs
  • Local Support Availability - Ensuring access to parts and technical support in your region

This balanced approach ensures that the selected platform not only meets current technical requirements but also provides a sustainable foundation for future operations and modifications.

HMI/SCADA Platform Experience

Effective human-machine interfaces are critical to safe and efficient turbomachinery operation. Our HMI/SCADA implementations focus on operational clarity, consistent navigation, and thoughtful alarm management to optimize operator effectiveness.

Rockwell Automation FactoryTalk View

We've implemented numerous FactoryTalk View SE and ME applications for turbomachinery controls, leveraging its tight integration with ControlLogix and CompactLogix controllers. Our implementations feature standardized faceplates and navigation systems that enhance operator efficiency.

Siemens WinCC & WinCC Flex

Our experience with WinCC includes both traditional SCADA implementations and distributed solutions using the WinCC/WebNavigator for enterprise-wide access. We've developed specialized turbine monitoring screens that present complex data in intuitive formats.

Wonderware InTouch

As a longtime industry standard, our InTouch implementations benefit from our deep knowledge of advanced scripting techniques and integration capabilities. We've created sophisticated turbomachinery applications that seamlessly connect with plant-wide Wonderware systems.

GE Proficy iFix

Our iFix implementations feature optimized database structures and efficient scripting to ensure responsive performance even in large applications. We've developed specialized driver interfaces for legacy turbomachinery systems to enable modern HMI capabilities.

HMI Design Philosophy

Regardless of the platform, our HMI implementations follow these core principles:

Situational Awareness

Screens are designed to provide immediate understanding of system status, with abnormal conditions made instantly recognizable through thoughtful use of color and position.

Consistent Navigation

Operators can quickly access needed information through intuitive navigation hierarchies that maintain consistency across all system areas.

Alarm Management

Alarms are prioritized and filtered to prevent overload during upset conditions, ensuring that critical information remains visible when needed most.

Our human-centered design approach results in interfaces that reduce operator fatigue, minimize error potential, and enhance overall system reliability.

Turbine Experience

HL Engineering Services brings specialized expertise in the control systems for critical industrial turbines. Our engineers have hands-on experience with multiple OEM platforms and have developed both OEM-compliant solutions and custom alternatives to address specific operational challenges.

Solar Turbines

Our experience with Solar Turbines spans multiple generations of their control systems, from early Turbotronic implementations through the latest Turbotronic 4 platforms. We've developed:

  • Custom HMI solutions that enhance operator visibility into turbine performance
  • Advanced control strategies for optimizing fuel efficiency while maintaining emissions compliance
  • Specialized interfaces between Solar control systems and plant DCS platforms
  • Migration strategies for upgrading legacy Solar control systems to modern platforms

Ruston, EGT, and Alstom

With deep knowledge of these European turbine platforms, we offer specialized expertise in:

  • Control system retrofits that extend the useful life of aging Ruston turbines
  • Modernization of EGT control systems to address obsolescence issues
  • Performance optimization for Alstom turbines in power generation applications
  • Custom control solutions that improve reliability while maintaining OEM compliance

"HL Engineering's turbine control expertise was invaluable during our critical retrofit project. Their engineers understood both the OEM requirements and our operational constraints, delivering a solution that improved reliability while maintaining compliance with warranty provisions."

— Plant Manager, Gulf Coast Chemical Facility

Driven Equipment Applications

Beyond turbine control systems, HL Engineering Services offers specialized expertise in the complete turbomachinery train, including driven equipment. This comprehensive approach ensures optimal performance of the entire system rather than isolated components.

Centrifugal Compressors

Our experience with centrifugal compressors spans applications from pipeline compression to process gas service in petrochemical plants. We've implemented sophisticated control strategies that address:

  • Surge prevention and detection with fast-acting protective algorithms
  • Performance optimization across varying operating conditions
  • Advanced sequencing for multi-case compressor applications
  • Integration with upstream and downstream process controls

Generators

For power generation applications, we provide control solutions that ensure reliable electricity production while maintaining grid compliance. Our expertise includes:

  • Synchronization and load-sharing controls for parallel generation
  • Grid code compliance including fault ride-through capabilities
  • Integrated excitation system controls
  • Load shedding and island mode operation strategies

Pumps

Critical pumping applications in the oil and gas industry require sophisticated control strategies to ensure reliability and efficiency. Our implementations feature:

  • Advanced pump protection algorithms to prevent damage during upset conditions
  • Energy optimization through intelligent speed control
  • Sophisticated alternation schemes for multi-pump installations
  • Integration with fire water systems for emergency response

Integrated Train Control Approach

Rather than treating turbines and driven equipment as separate entities, our engineers take a holistic view of the entire train. This approach enables:

Optimized Startup/Shutdown

Coordinated sequences that properly account for thermal considerations and mechanical constraints across all equipment

Comprehensive Protection

Integrated safety systems that consider interactions between prime mover and driven equipment during abnormal conditions

Efficiency Improvements

Control strategies that optimize the entire train rather than sub-optimizing individual components

Machinery Protection & Specialized Systems

Protecting critical turbomachinery assets requires specialized systems that operate independently from primary process controls. HL Engineering Services provides expertise in these crucial protection systems that form the last line of defense against catastrophic equipment damage.

Vibration Monitoring and Protection

Our engineers have implemented numerous vibration monitoring solutions using platforms from Bently Nevada, Metrix, and other specialized vendors. These systems provide:

  • Continuous monitoring of critical vibration parameters
  • High-speed data acquisition for transient event capture
  • Sophisticated alarming with multiple threshold levels
  • Integration with historians for long-term trend analysis

We also develop custom integrations between these specialized systems and plant-wide control systems, ensuring operators have visibility into machinery health while maintaining the independence of protection functions.

Over-speed Trip Systems

Preventing catastrophic turbine failures due to over-speed conditions requires highly reliable, independent protection systems. Our experience includes:

  • Triple Modular Redundant (TMR) electronic over-speed protection
  • Mechanical bolt systems with electronic monitoring
  • Hybrid systems combining electronic and mechanical protection
  • Testing procedures that validate protection without disrupting operations

We ensure these critical safety systems meet applicable industry standards while providing practical solutions for testing and maintenance.

Fire & Gas Systems

Protecting personnel and equipment from fire and hazardous gas releases is paramount in hydrocarbon processing facilities. Our capabilities include:

  • Specification and design of fire and gas detection systems
  • Integration with turbomachinery emergency shutdown systems
  • Cause and effect matrix development and validation
  • Compliance verification with industry standards (NFPA, IEC, etc.)

Our approach emphasizes both reliability and practical maintainability to ensure these systems function when needed most.

System Independence and Integration

While maintaining the necessary independence of protection systems, we also develop appropriate interfaces to operational systems, balancing safety requirements with operational visibility. This approach provides:

  • Clear visibility of protection system status for operators
  • Historical data capture for event analysis and trending
  • Maintenance diagnostics without compromising protection
  • Centralized alarm management without creating common failure points

Our designs adhere to the principles of functional safety while providing practical solutions that can be effectively maintained throughout the system lifecycle.

Partner with HL Engineering Services

When you choose HL Engineering Services for your turbomachinery control needs, you gain a partner committed to your operational success. Our approach combines technical excellence with practical, field-proven solutions that address the real-world challenges of industrial facilities.

Why Our Clients Choose Us:

Deep Industry Expertise

Our engineers average over 20 years of hands-on experience in turbomachinery controls, bringing valuable insights to every project.

Vendor Independence

As an independent consulting firm, we provide unbiased recommendations based on technical merit rather than vendor relationships.

Practical Solutions

We balance theoretical excellence with practical implementation, delivering solutions that work reliably in challenging industrial environments.

Lifecycle Perspective

Our recommendations consider not just initial implementation but long-term supportability and future upgrade paths.

Ready to Discuss Your Turbomachinery Control Needs?

Contact our team today to schedule an initial consultation. We'll discuss your specific challenges and objectives, and explore how our expertise can contribute to your operational success.

"What impressed us most about HL Engineering was their ability to translate complex technical concepts into practical solutions that our operations team could easily understand and maintain. Their work significantly improved our turbine reliability while reducing maintenance costs."

— Maintenance Director, Major Power Generation Facility