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Petroleum
Refining
Electrical, Instrumentation, Controls,
and Analytical
Emerson Process Management
personnel have extensive experience in petroleum refineries. Project experience
includes the major processing units within a refinery, as well as projects that
occurred outside the battery limits. Many of our engineers also have day-to-day
troubleshooting and operational knowledge of refineries, having been previously
employed by the major companies in the business. Our safety record is excellent,
with an enviable experience modification rating, and we have won several safety
awards from customers.
Hydrocracking
& Alkalization Units - Prepared DCS specifications, factory acceptance
test procedures, commissioning procedures and display graphics guidelines.
- Developed,
loaded and modified DCS point and system databases. Supervised the development
of all DCS display graphics. Participated in on-site acceptance testing and commissioning
activities.
- Designed the motor control centers (all 480V load). Also designed
the cable tray, lighting and grounding systems, and heat tracing systems.
- Designed
Rag layer detection for HF / organic separator.
Catalytic
Cracking - Specified and designed redundant field instrumentation
and shutdown system for a new oxygen pipeline used for catalyst regeneration.
- Designed,
specified and loop-checked pump minimum flow recycle instrumentation for water
sprays.
- Designed, specified and checked-out new level instrumentation
for waste heat recovery steam drum.
Catalytic Light
Ends - Designed all electrical and power systems for new
gas fractionation and propylene separation units.
- Developed PLC control
system for the emergency shutdown system.
- Design included 480V MCCs, cable
tray, lighting and grounding.
- Vapor pressure measurement design
Crude
Distillation - Converted a 180,000 bbl/d distillation unit
and a 90,000 bbl/d distillation unit to a new DCS system and consolidated
the units into a central control room.
- Moved approximately 2000 new and
existing points and loop-checked to the new system.
- Loop check and start
up of the new system as well as the instruments.
- Analyzer design
Sulfur
Recovery and Off-Gas Treating Units - Scope development,
design, specification, configuration, checkout, startup and cutover of pneumatic
instrumentation system to electronic transmitters and a new DCS system
- One-half
of the 1,000 I/O devices were cut over hot and the other half during scheduled
turnarounds. After cutovers were complete operator stations, communications systems
and hard-wired interlocks were relocated to a new control room.
- Auxiliary
systems included a safety interlock system, a Bently Nevada machinery
monitoring system, process and environmental analyzers, flame detectors and burner
ignition controls, and backup power systems.
- Developed specialized project
instrument database that minimized drafting requirements.
- Analyzer design
Lube
Oil Unit - Automated the drum line for motor oil utilizing
six Allen-Bradley PLC-5's.
- Developed the operator interface graphics package
for the new computerized control system.
- Designed and installed new drum
filling scales, 200 photoeyes, and four bar code label scanners.
- Physical
property / viscosity measurement and control
Oil Movement
& Storage / Gasoline Blending - Refinery-wide tank farm
study for OM&S system upgrade.
- Turnkey design of gasoline blending
systems. Experiences include process design, analyzer design, control systems
upgrade and instrumentation design.
- Residium measurement and control.
Terminal
Management Solutions (TMS)
Asphalt,
Light Oils and Propane Loading Rack - Upgraded the instruments
and automated the loading rack in a Y2K compliance project.
- Automation
included new equipment such as Load Cells, Gate Controls, Card Reader, Fiber Optics,
Analyzers and piping modifications.
- Interfaced devices with existing flowmeters,
gate controls weigh scales and ticket printers.
Tank
Farm Automation - Replace a number of single loop controllers
with two new DCS systems
- Continuous level monitoring via radar level transmitters
(4-wire transmitters)
- Temperature control via suction heaters or tank
steam coils
- Pump shutdowns via DCS
- Manual by-passes installed
around the level interlock(s)
- Fabricated the DCS control panels
- Current
projects to link owners PC to each DCS via ethernet using fiber optic and the
integration of data into the tank plant inventory reporting system
Boiler
House - Identified required equipment and instrumentation
to upgrade existing boiler controls. Developed scope of work and detailed estimate
to replace existing control system with Distributed Control System (DCS).
- Coordinated
the design and estimated construction cost of a new blast-proof control building
to house the new DCS.
- Designed and installed soft water treatment system
using Modicon PLCs with hot backup and PC Graphic interface.
- CEMS Design.
Other
Refinery Projects - Updated Electrical Area
Classifications
- Developed Electrical Area Classification
drawings based on API and NFPA guidelines using Fugitive Emission data.
- Analyzed
pump seal failure leaks to determine large sources of hazardous gases.
- Generated
a comprehensive database to be used with the Electrical Area Classification drawings
identifying the source and extent of hazardous areas.
- Updated Existing Documentation
- Field
verified existing instrument loops and created CAD drawings.
- Verified
critical loops and wrote operating description and test procedures.
- Updated
Instrument Index based on field verifications.
- Updated Process And Instrument Drawings (P&ID's)
- Field
verified instruments, piping & equipment and converted P&ID's to CAD drawings
in fifteen operating units.
- Updated Instrument Index based on field verifications.
- Developed
power, power distribution and co-generation projects.
- Replaced
field alarm panels for compressors.
- Added redundant transmitters
to ensure reliability of hydrogen service. Designed and installed two out of three
voting logic.
- Provided Safety liaison services to local
refinery.
- Provided coker heater system analyzer design
- Materials
purchasing for turnarounds
- Refining controls engineering
projects on various process units throughout the plant
Other
Refinery Projects
- Aramco
- Arco
- BP / Amoco
- Chevron
- Citgo
- Clark
/ Premcor
- Conoco
- Elf
- ExxonMobil
| - Fina
- Imperial
- Koch Refining
- Kuwait
National Petroleum Co.
- Petrobas
- PetroPeru
- Phillips Petroleum
- Shell Oil
- Sun Oil
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