Emerson Process Management - Industries - Chemical

Detailed Cutover Planning Leads to Successful Turnaround for a Chemical Plant

Emerson Process Management was awarded a lump sum project to replace an existing Rexnord D3 DCS system with DeltaV. The scope of work required the configuration team to convert the software to DeltaV and successfully cut the system over during a planned 5- day turnaround of the PTA unit.

The existing system was interfaced to other Foxboro, Allen Bradley and Honeywell systems through shared I/O and serial communication links. Intrinsic safety barriers protected field-wiring signals for instruments located in hazardous areas. Several systems had been added over the years and no additional room was available to add any new equipment. The project required removal of the Rexnord D3 system during the turnaround so the cutover team could install, commission and startup the new DeltaV system.

Older style MTL Intrinsic safety barriers presented challenges as well as various grounding methodologies because of the different DCS vendors installed in the same control room. The versatility, communication capabilities and small footprint of DeltaV allowed the engineering team to design a system that integrated in the exiting plant.

Emerson's approach was to prepare detailed cutover procedures and work with the client to organize activities by all parties. Contingency plans were developed to support cutover activities. Emerson managed the construction team at the site. Emerson also implemented and tested application software near the client's facility to allow plant personnel easy access to the development team. Signal wiring was cut over and commissioned for startup. Emerson also supported activities during initial startup of the unit.

The Plant Manager recognized the Emerson Team for a well-executed project that allowed the client to meet their product delivery schedules.

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Problem:

A large chemical company based in North Carolina needed to cut over a PTA process. controlled by an older model Rexnord D3 DCS system. The project was placed on a fast track schedule so that the replacement would occur within a 5-day turnaround of the unit. The minimal space available to install new equipment and interface to existing intrinsic safety barriers, Honeywell and Foxboro systems created a challenge for the engineering team.

Solution:

The client turned to Emerson Process Management to execute and manage design, construction and implementation of a new DeltaV control system to control the PTA process. Detailed planning and execution of the cutover successfully replaced the system less than the 5 days allowed.

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