HYDROPROCESSING UNIT PROCESS CONTROL MODERNIZATION
Shell Deer Park Refinery Company - Deer Park, TX

Emerson Process Management was awarded a contract by Shell to provide process control equipment, engineering and procurement services, and construction for the re-instrumentation of the Hydroprocessing units, Selective Hydrocracker (SHCU)-Hydrogen Plant 1 (HP1)-Process Swing Absorber (PSA)-Catalytic Reformer 3 (CR3), at the Deer Park refinery. The objective was to replace existing pneumatic, electronic single-loop instrumentation, PLC and relay-based shutdown systems with a DCS and safety system, and relocate operators to a central refinery control building. The project scope involved working with multiple vendors, contractors, and refinery support groups to accomplish the objective, within the Shell specified dates. The project was divided into three phases, two turnarounds and one hot cutover, to accommodate two scheduled turnarounds. The engineering work was executed on-site and at two remote Emerson industry centers.

Emerson was selected because it has previous experience with re-instrumentation projects. Further project details follow.

• Develop control system requirements for the Hydroprocessing units, on a "replace-in-kind" basis.
• The design incorporate DeltaV controllers and Foundation Fieldbus field devices, including control in the field.
• Replace relay based ESD system with new triple redundant system, Triconex, including new field devices.
• Replace existing turbo-machinery vibration monitoring devices with new controls and field devices.
• Engineer, purchase and install over thirty-five hundred new field devices.
• Cutover to DeltaV and Foundation Fieldbus control while the units are running.
• Conducted P&ID walk-downs to determine the "as-found" state of the units.
• Conducted P&ID reviews with the client's engineering and operations personnel to verify the "as-found" state of the units.
• Conducted additional P&ID reviews to determine requirements for units after the re-instrumentation was completed. This included developing a Shell standard for depicting the new Foundation Fieldbus Rosemount transmitters and Fisher Controls DVC valve positioners.
• Worked with the client's engineering and operations personnel, determine the scope of the emergency shutdown systems and compressor speed and surge controls.
• Provided all documentation for Independent Project Analysis (IPA) review.

• Provide an AFE quality estimate in support of Shell funding project plans.
• In conjunction with the PI&D reviews, developed a project instrument database that was used for all aspects of the engineering and design work. The database will be converted to INtools format for long-term use by Shell. INtools will be used to generate loops drawings, instrument specifications, etc. for the project. This involved developing what would become Shell Deer Park's INtools standard spec sheets, loop drawings, Fieldbus segment drawings, etc. Documents generated will be used for installation, loop checkout, and hot cutover. At the end of the project the INtools database will be used to generate "run and maintain" documents.
• Design and provide three remote instrument enclosures for DCS, ESD, and peripheral systems.
• Provide civil, structural design for the three remote instrument enclosures.
• Provide piping design for new level bridles required by the installation of new transmitters.
• Determine requirements and provide new machinery vibration monitoring systems for three compressors.
• Work with client's electrical support personnel to specify uninterruptible power system and power distribution panels.
• Provide complete configuration for control system, including control functionality, operator graphics, and complex loop control schemes.
• Design communications system and provide hardware and software to allow for the use of OPC to integrate the following systems: DeltaV, ESD, vibration monitoring, historical data collection, AMS, etc.
• Provide installation material and labor to install, test, and cutover all new cable tray, instrument and power cables, junction boxes, RIE, FFB field devices.
• Provide loop/segment checkout personnel, using Shell approved lop and segment checkout procedures.
• Provide project schedules and cost reporting throughout the entire project.
• Conduct Shell/Emerson weekly project team meetings to review.
  

			Gas Blending: Emerson Process Management can provide a number of digital blending solutions within a petroleum refinery. Hot Cutover Capabilities View Emerson Process Management Hot Cutover Capabilities(364 KB) PDF Read More
			Shell HUPCM: Emerson Process Management was awarded a contract by Shell to provide process control equipment, engineering and procurement services, and construction for the re-instrumentation of the Hydroprocessing units. Shell CC&G Reinstrumentation: Emerson Process Management was awarded a contract by Shell to provide process control equipment, engineering and procurement services, and construction for the re-instrumentation of the Cat Cracker and Gas Fractionation units at the Deer Park refinery. Read More

      Explore career opportunities