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SULFUR & SCOT UNITS REINSTRUMENTATION
Equilon
Wood River Refinery - Wood River, IL
Emerson
Process Management's Refining & Chemical Industry Center was requested by the Equilon instrument/electrical
project manager to take the lead design and startup role for a project in the
sulfur recovery and SCOT (Shell Claus Off-gas Treating) units at a major midwestern
refinery. The objective was to replace existing pneumatic instrumentation and
relay-based shutdown system with a DCS and safety system, and relocate operators
to a new control building. The project scope, not clearly defined up front, involved
working with multiple vendors, contractors, and refinery support groups to accomplish
the objective with minimal capital and in limited time. All of the work was done
on-site. The project was halted when the refinery was being sold, and then restarted
and completed. Emerson personnel simultaneously managed or supported multiple
other projects throughout the refinery. Emerson was selected due to previous
experience on reinstrumentation projects. The following provides further detail
regarding the project.
Conceptual Design
- Held P&ID review meetings with the client's engineering and operations
personnel in order to scope Distributed Control System (DCS).
- Held shutdown
system logic review meetings with the client's engineering and operations personnel
in order to scope Safety Instrumented Systems (SIS).
- Developed a project
instrument database and reports summarizing disposition of all instrumentation
(approx. 1000 hard-wired I/O).
Detailed Design
- Assembled DCS scope and obtained pricing from client's preferred vendor. Included
remote instrument enclosure for DCS and peripheral systems.
- Assembled
SIS scope and obtained bids from two vendors (client did not have a standard SIS).
Worked with client engineering personnel to evaluate and select the vendor.
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Worked with client's mechanical equipment support personnel to specify a machinery
vibration monitoring system (3 blowers).
- Worked with client's electrical
support personnel to specify uninterruptible power system and power distribution
panels.
- Implemented new client standards for open tray wiring to field
devices, mostly in Class I Division 2 areas.
- Client requested minimal
drawings, including loop drawings only for unusual loops, so Emerson designers
developed new drawing templates and standards.
- Lead role for configuring
DCS points. Worked with client control systems engineering personnel on graphical
interface, alarm historization, and complex loop configuration.
- Ordered
DCS, RIE, SIS, field instrumentation, and services through the client's on-line
purchasing system (systems changed after the refinery was sold).
SCOT
Unit Cutover - Worked with Black & Veatch Pritchard
personnel on partial process revamp.
- Supported construction and loop
checks by client's construction contractor.
- Supported cold startup of
unit on new DCS in old control room, including loop tuning.
Sulfur
Trains Cutovers - Worked with client operations personnel
to develop loop hot cutover sequence and detailed cutover instructions.
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Supported construction and loop checks by client's construction contractor.
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Most loops were cutover to DCS and SIS in old control room while process was in
operation.
New Control Building
- Worked with client's architect on design of new control building and control
room.
- Building not completed until loop cutovers had already been completed.
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Lead role managing relocation of DCS console from old control room to new one,
with all loops and SIS in operation during the relocation.
As-Built
Documentation - Updated P&IDs, logic drawings, and
wiring drawings.
- Supported client personnel with transfer of project
instrument database to refinery on-line maintenance system.
- Developed
"complex loop" documentation.
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