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CATALYTIC CRACKING & GAS 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 Cat Cracker and Gas Fractionation units 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 two phases to accommodate a previously scheduled cat cracker turnaround. 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. Conceptual
Design - Develop control system requirements for the cat cracker and gas fractionation 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, including new field devices.
- Engineer, purchase and install over one thousand 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.
Detailed
Design - Provide two AFE quality estimates in support of Shell funding project plans.
- 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.
- Working with the client's engineering and operations personnel, determine the scope of the emergency shutdown systems and compressor speed and surge controls.
- 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 was converted to INtools format for long-term use by Shell. INtools was 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 remote instrument enclosure for DCS, ESD, and peripheral systems.
- Provide emergency generator to power DCS and ESD system as needed.
- 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 check-out personnel, using Shell approved lop and segment check-out procedures.
- Provide project schedules and cost reporting throughout the entire project.
- Conduct Shell/Emerson weekly project team meetings to review.
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