Sagacity, a Houston-based powerhouse in Design, Engineering, Fabrication, Installation, Commissioning, and Long-Term Support, stands as a beacon in providing essential Components and Services for facilities striving to operate efficiently and safely. With an inherent understanding of the intricacies of the process industries, Sagacity caters to a diverse clientele spanning Chemical, Refining, Petrochemical, Manufacturing, Water and Waste Water, Mining, Food and Beverage, Transportation, Power, Renewables, Carbon Capture, and beyond.

Underlining their commitment to excellence, Sagacity's seasoned team of professionals, with decades of collective experience in the process industries, brings unparalleled expertise. Their proficiency not only encompasses mastery of cutting-edge technologies but also extends to a profound understanding of older technologies, offering unique insights into seamlessly integrating the old with the new.

Whether it's assisting in the initial stages of a project or spearheading the entire process from feasibility to fabrication, Sagacity emerges as a reliable partner for clients seeking optimization in their projects. The company’s holistic approach and dedication to client success position them as more than just a service provider – they are your resource for comprehensive engineering and fabrication solutions.

In an exclusive interview with CIO Bulletin, Rusty Darsey, CEO of Sagacity, highlighted how he and his team of seasoned engineers and fabrication specialists are employing cutting-edge technology to design, engineer, fabricate, install, and commission complete purpose-built systems.

Interview Highlights

Q. Can you provide a brief overview of how and when Sagacity was founded? What inspired the establishment of the company?

Sagacity was incorporated in June 2018 in response to prospective clients searching for a cost-effective engineering and manufacturing partner to handle small to medium-sized projects. Larger EPCs were charging rates that rendered their projects cost-prohibitive. Additionally, clients lacked the fabrication capabilities to manage the construction, installation, or commissioning once designed. Sagacity manages the design, engineering, and fabrication with a single purchase order.

Q. Could you brief us about the range of products and services that Sagacity offers to its clients across various industries?

Sagacity’s business model is unique. We can design, engineer, fabricate, and even install and commission many different types of systems. We define our markets by describing them as the process industries. Process industries encompass anyone involved in taking something and transforming it into something else – from natural gas to plastic, oil to gasoline, water and other components to food production, and wood byproducts to fuel manufacturing. In total, we cover over 20 different markets and hundreds of applications.

Q. What innovative engineering and fabrication technologies does Sagacity employ to stay ahead in the competitive market?

We utilize 3D modeling (AutoCAD Plant 3D) for all our design and engineering efforts. Clients appreciate the ability to visualize the end product, and it greatly aids in maintaining alignment during the design phase of a project. In the automated systems we construct, we strive to incorporate AI as much as possible. For instance, in Asset Monitoring Systems, machine learning plays a pivotal role in minimizing client downtime to virtually nothing.

Q. In industries with strict safety and compliance regulations, how does Sagacity prioritize and maintain a strong safety culture?

Safety and sustainability are our two main cornerstones. Everything we design and build prioritizes the client’s safety. For instance, when creating an electrical panel layout, we ensure the panel is organized, well-labeled, and compliant with best industry practices, meeting the latest electrical code standards. Incorporating the latest standards into our design software is also crucial. Staying current with the best industry practices and standards not only ensures our clients remain compliant but, more importantly, safe.

Q. Given the dynamic nature of the industries served, how does Sagacity adapt to changing market conditions and client requirements?

Our engineering staff stays attuned to industry trends by participating in Continuing Education Unit (CEU) courses relevant to the process industries. We actively engage in various industry events, such as the upcoming Carbon Capture Congress, to gain insights into current best practices and future industry trends. Additionally, our involvement in industry organizations like OGGN (Oil and Gas Global Network) and ISA (International Society of Automation) includes regular attendance at monthly events and podcasts. This proactive approach ensures we remain well-informed and connected with professionals who set benchmarks both at a technological level and in understanding client needs.

Q. Can you share one or two client success stories where Sagacity's services resulted in measurable improvements or achievements for the client? What were the key success metrics?

Chemical Delivery Challenge

The Problem: Our client, a manufacturer of chemicals for the refining process, was grappling with a significant issue in their chemical delivery system. The existing setup, relying on an outdated positive displacement flow meter mounted to the rear of their tanker trailers, consistently resulted in discrepancies between delivered and reported quantities. Manual operations compounded the problem, hindering the accurate tracking of chemical deliveries.

Sagacity to the Rescue: To address this challenge, Sagacity designed and implemented a revolutionary solution – a compact chemical delivery system, or 'flow metering skid,' incorporating the latest flow technology. This innovative system not only resolved the discrepancies but also seamlessly tied into both the client’s system and their home office for billing. The outcome was a streamlined process where clients received precisely what they ordered, and billing happened automatically at the time of delivery. This intervention not only rectified the immediate issue but also significantly enhanced the overall efficiency of chemical deliveries.

Proactive Asset Monitoring Initiative:

The Problem: In another scenario, a client approached Sagacity with a pressing need to monitor the health of their operational assets in an aging facility. While they had systems in place to monitor manufacturing processes, there was a critical gap in effectively assessing the health of system assets such as blowers, compressors, and boilers.

Sagacity’s Unique Approach to Resolve the Problem: Sagacity responded by designing a comprehensive solution – a plant-wide PLC-based system that wirelessly connected all monitoring asset information. This data was transmitted to the cloud, enabling real-time monitoring of each asset. Operational parameters were set, live displays were developed, and the maintenance department gained the ability to monitor assets proactively. With alarms and notifications in place, the maintenance team could address issues before they escalated, putting an end to all run-to-failure incidents. The remarkable outcome was zero downtime reported after the first year, saving the client over $2 million in lost production time incidents. Sagacity's innovative approach not only met but surpassed expectations, transforming the client's asset management practices and ensuring seamless operations.

Q. How does the company plan to stay at the forefront of the engineering and fabrication industries in the coming years?

As mentioned earlier, we are committed to staying on top of emerging markets such as Hydrogen and Carbon Capture, among others. Additionally, we continuously strive to be early adopters of new design and modeling techniques, incorporating AI and other practical software tools into our processes. Furthermore, our active engagement with esteemed organizations such as API, AGA, UL, ASME, and others that set benchmarks for best practices ensures that we remain abreast of industry trends and adhere to the highest standards.

Q. What message would you like to convey to the readers of CIO Bulletin and to your current and future clients?

Sagacity is dedicated to bringing stalled or moderately funded projects to life, offering a flexible approach tailored to the specific needs of our clients. Whether it's providing comprehensive support or addressing specific aspects of a project, our aim is to see our clients succeed. Leveraging modern technologies, we ensure applications are handled in the most cost-effective manner possible. Often, we collaborate closely with customer engineers, offering assistance where needed and providing fabrication services they may lack internally. Our goal is to be a valuable resource in any capacity that makes sense for their situation, guiding them towards the successful realization of their objectives.

Rusty Darsey | Founder & CEO

With over 38 years of experience, Rusty Darsey has dedicated his career to constructing purpose-driven systems for clients worldwide. His extensive applications expertise, combined with the seasoned staff at Sagacity, offers clients access to over 200 years of collective experience. This wealth of knowledge empowers them to fabricate tailored solutions that precisely meet their needs.

“Sagacity is dedicated to bringing stalled or moderately funded projects to life, offering a flexible approach tailored to the specific needs of our clients. Whether it's providing comprehensive support or addressing specific aspects of a project, our aim is to see our clients succeed.”