Sour Gas Processing Plant DCS Upgrade

INDUSTRIES
  • Oil Sands & Heavy Oil
SERVICES
  • Training
  • System Lifecycle Studies
  • SIS
  • Project Management
  • Electrical Design
  • Document Management
  • Detailed Engineering
  • DCS
  • Custom Applications
  • Control System Migration
  • CheckMate
TECHNOLOGIES
  • Training
  • System Lifecycle Studies
  • SIS
  • Project Management
  • Electrical Design
  • Document Management
  • Detailed Engineering
  • DCS
  • Custom Applications
  • Control System Migration
  • CheckMate

The Challenge

The client operates an industrial gas processing facility located in west central Alberta. Initially, a lifecycle study was conducted in order to determine the future direction for the plant control systems. In response to the control system life plan, the client chose to move forward and fund the migration of the current Fisher PROVOX system to a new Emerson DeltaV DCS.

Autopro’s Role

While this initiative was viewed as a single project by the client, Autopro approached the upgrade in two phases. The first phase was a thorough documentation review and update, as the plant had virtually no existing documentation and several years of ‘patchwork’ rewiring. The second phase was the controls migration to the modern control system.

The main objectives for the controls system migration were as follows:

  • Replace the existing operator stations (HMI) with Windows XP based stations operating with DeltaV HMI software.
  • Replace the existing Fisher PROVOX control system with Emerson DeltaV.
  • Transition to the new control system through a combination of an online swingover process through the summer of 2010, and an offline swingover during a scheduled plant shutdown in the fall of 2010. This schedule was critical as unplanned downtime is very expensive; therefore, the plant had to come back online immediately following the fall shutdown activities.

Autopro was initially tasked with the responsibility of completing a control system life cycle study. During the execution of this project, every process area in the facility was affected. Autopro’s responsibilities included overall project management, electrical and instrumentation detailed engineering, procurement support, software development and implementation, graphics migration, controls check out and commissioning, operations training, and startup support.

Success Criteria

The client defined the following success criteria:

  • Migrate 75% of plant on-line, Migrate 25% off line
  • Schedule - met clients 9 day shutdown window for the entire plant
  • No additional downtime beyond scheduled plant outage

The actual project outcomes included:

  • All control system configuration was tested prior to 100% prior to migration beginning
  • 99% of all I/O was migrated on-line without control systems incident.
  • 1% of I/O was migrated during client shutdown
  • Start-up occurred without issue
  • On-line migration was completed 2 months ahead of schedule

Project Metrics

Project Completion Date