DCS Upgrade

INDUSTRIES
  • Oil & Gas
SERVICES
  • Project Management
  • Operations & Maintenance Technical Support
  • Networks & Connectivity
  • Instrumentation Engineering
  • HMI
  • HAZOP / CHAZOP
  • FEED
  • Electrical Design
  • Drafting
  • Detailed Engineering
  • DCS
  • Controls Commissioning Services
  • Control System Migration
  • Construction Package Development
  • Construction Management
TECHNOLOGIES
  • Project Management
  • Operations & Maintenance Technical Support
  • Networks & Connectivity
  • Instrumentation Engineering
  • HMI
  • HAZOP / CHAZOP
  • FEED
  • Electrical Design
  • Drafting
  • Detailed Engineering
  • DCS
  • Controls Commissioning Services
  • Control System Migration
  • Construction Package Development
  • Construction Management

The Challenge

The client operates a large natural gas plant near Rainbow Lake and co-owns/operates a cogeneration facility. In order to minimize the risk of downtime at its processing plant, the client previously upgraded its operator HMI and controllers to Emerson DeltaV hardware. Emerson planned to stop supporting PROVOX hardware, so an online migration of the remaining 2,000+ I/O from PROVOX to DeltaV was needed to eliminate the requirement for a long outage. The client faced limited site resource availability and required a dedicated consultant to undertake this project.

Autopro's Role

Autopro was selected to manage the project, which was implemented in phases. For each phase, a scope and cost estimate was defined and submitted to the client's management for review and approval. Autopro was initially tasked with developing detailed costs estimates for each phase; this ultimately led to executing the project and assisting with the management of each phase. 

DeltaV CHARM I/O was selected as the solution for the migration because of its ability to install different I/O types as required and provide a solution for PROVOX termination panel migration. Given the limited amount of space available in the MCCs and to minimize re-wiring, the DeltaV CHARM I/O migration panels were also selected.

To minimize risk, a CHAZOP was performed, which revealed that DeltaV CHARM I/O represented a change in philosophy for the control system that needed to be evaluated from a hazards and risk perspective. As a result of the CHAZOP, certain issues and concerns were raised that were addressed during detailed design.

During the execution of this project, virtually every process area in the facility was affected. Autopro’s responsibilities included overall project management, electrical and instrumentation detailed engineering, procurement support and materials management, software development and implementation, controls checkout and commissioning, operations training, and startup support.

Autopro’s work for each phase involved:

  • Phase 1: The existing DeltaV software had to be migrated from version 9.3 to version 11.3, which also meant an upgrade in the operating system (Windows Server 2003 to Windows Server 2008; Windows XP to Windows 7). This also meant that all of the existing server software (e.g., SCADA, alarm logging, data historian, etc.) all had to be upgraded for the new operating system.
  • Phase 2: Approximately 100 pneumatic end devices were connected to the PROVOX DCS using P/I and I/P converters. This phase involved replacement of the pneumatic end devices with electronic 4-20 mA equivalents (transmitters and smart positioners) re-wired to new CHARM I/O. This allowed site personnel to become familiar with the new CHARM I/O on a staged basis. Autopro specified and obtained quotes for the new devices, which were purchased by the client.
  • Phase 3: Migration of the existing PROVOX I/O to CHARM I/O in four areas (Waterflood, Sour Gas, Utilities, and Acid Gas). Approximately 50% of the I/O was migrated online. The balance was migrated during the plant turnaround.

Success Criteria

Given the remote location of the site, weekly teleconference meetings were held for the duration of the project. This ensured that both the client and Autopro were aware of any design issues as well as provided a weekly forum for discussion of the action/decision list. Communications between client site personnel and Autopro was one of the keys to the success of this project. Onsite Autopro personnel for each phase of the migration contributed to the success of the project by allowing Autopro to review work plans with site personnel and address any issues that arose during implementation.

Project Metrics

Project Completion Date