Pilot Chemical Company: Control System Migration

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Pilot Chemical Company’s main sulfonation plant used two major control systems to run their process. One half of the process was controlled by Emerson’s DeltaV DCS, and the other was controlled by a network of Rockwell’s PLC -5s and Intellution’s® SCADA HMI software.

CSA was tasked with providing a turn-key solution that would replace the PLC-5s and SCADA system while consolidating both process areas into one distributed control system.

We elected to virtualize all operator and engineering workstations with high available servers and a client network. To reduce the switch-over time of a 2400 I/O point process, CSA utilized pre-made plug-in vendor cable with DeltaV high-density IO and DeltaV CHARM remote IO as necessary. The switch-over was further complicated by the requirement to maintain operation of the existing DeltaV DCS and allow trucking operations to continue in the migration area.

Pilot Chemicals estimated and prepared for a 10–12 day shutdown. We completed the switch-over in 7 days.

Plant Manager Mike Bizzarro said of his experience with CSA:

We chose them in part because their proposal was so comprehensive and detailed. They had clearly put a lot of time and thought into planning a trouble-free migration.

They had all the capabilities they promised, and the people they brought in showed real buy-in to the overall success of the project. The migration went smoothly, and for the few minor issues we had afterward, they were really good about getting them corrected. We got good value.

Pilot, Before CSA

Pilot, After CSA

New DeltaV Panel

New SS Panel

Services Provided:

  • Project management and construction management
  • Development of plant configuration standards
  • Development of all functional specifications
  • Specification and procurement of all hardware and system software
  • Configuration of control modules and sequences for a 2400-point process
  • Development of 90 process displays
  • FAT and SFAT testing
  • Engineering and operator training
  • E&I installation
  • Switch-over management
  • Loop checks and commissioning
  • Start-up assistance

BASF: Ethoxylation Plant

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BASF wanted to improve the safety of its South Carolina ethoxylation plant, so they called on CSA.

In the ethoxylation process, ethylene and propylene oxide react with a variety of alcohols. The reaction is highly exothermic and requires an advance control strategy to prevent a runaway reaction. To enhance security, BASF decided to relocate local control to a central control. They also decided to remove one of their older reactors from service and convert the remaining three reactors to a reactor train.

We were the project manager for all design and installation of instrumentation and electrical equipment. We designed the new control room and specified all DCS and safety PLC equipment. And we developed the functional specification for batch and continuous control strategies.

We configured the DeltaV system and developed the operator display. And we handled start-up services. We stayed on-site until our engineers and the client were certain that everything had been properly configured and was operating as designed. When we left, BASF was delighted with the results, and we felt good knowing we had made the plant so much safer.

Services Provided:

  • Project management of all design and installation of instrumentation and electrical equipment
  • Design the layout of the new control room
  • Specified all DCS and safety PLC equipment
  • Provide functional specification for batch and continuous control strategies
  • Continuous and batch configuration of DeltaV system
  • Operator display development
  • Conventional I/O, Stahl IS.1 remote I/O
  • Electrical construction management
  • On-site startup services
  • Control system: Emerson DeltaV

BASF: DSX Polyurethane Plant

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BASF needed a North Carolina plant to produce DSX® 1514/1550 polyurethane. The process is complex, requiring advanced automation procedures, so they called in CSA.

To produce DSX® polyurethane, which gives latex better hiding power in brush applications, a pre-polymer is made from isocyanate and ethoxylated nonylphenol in toluene. The pre-polymer is then reacted with polyethylene glycol to cap the molecule. Excess solvent is stripped off and the product is passed thru a finishing process. The process is a two-procedure batch process utilizing four units to complete the reaction and finishing.

We wrote the specification of all DCS hardware and software, reviewed all instrument and electrical equipment specifications, and reviewed all design documentation from the third-party engineering firm. We also provided the functional specification for batch and continuous control strategies.

We then configured the Emerson DeltaV system and developed the operator display. We also provided operator DCS training and supported the on-site startup.

The facility start-up went smoothly, and BASF got to work supplying the demand for DSX® 1514/1550.

Services Provided:

  • Specification of all DCS hardware and software
  • Review of all instrument and electrical equipment specifications.
  • Review of all design documentation from third-party engineering firm
  • Provide functional specification for batch and continuous control strategies
  • Continuous and batch configuration of DeltaV system
  • Operator display development
  • Conventional I/O, Foundation Fieldbus, ASi, Profibus
  • Electrical construction management
  • Operator DCS Training
  • On-site startup services
  • Control system: Emerson DeltaV

BASF: Distributed Control System Conversion

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A major Care Chemicals plant wanted to convert its existing Rosemount RS3 distributed control system to Emerson’s DeltaV DCS while expanding into a new process area. The existing area would remain with conventional I/O while the new process area would utilize AS-i and Foundation Fieldbus technology.

Since the plant was in a sold-out position, the conversion had to take place during a 10-day window between the Christmas and New Year’s holidays. CSA’s extensive team of field experts was able to complete the project and bring the plant back online in the promised timeframe. CSA was responsible for developing all functional specifications, system configuration, and commissioning.

Services Provided:

  • Configuration of control and equipment modules for a 2200 point process
  • Configuration of conventional, Foundation Fieldbus, and AS-I I/O types
  • Development of over 65 operator displays
  • FAT testing
  • Loop checks and commissioning
  • Start-up assistance

BASF: Defoamer Production Plant

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In order to meet a high sales forecast, BASF needed a new 24-million pound-per-year defoamer production facility in North Carolina… and they needed it up and running in less than 10 months. So they called in CSA to get the job done right and on time.

We developed all specifications for DCS hardware and software, and the functional specifications for batch and continuous controls strategies. We reviewed all electrical and instrument equipment specifications and managed all electrical construction. And we reviewed all design specifications from the third-party engineering firm.

We configured the DeltaV control system as well as all conventional I/O, Foundation Fieldbus, ASi, and Profibus. And we developed a custom operator display.

We handled all operator DCS training and provided onsite startup services.

The facility was operational on schedule and allowed BASF to meet the demand its robust sales effort had created.

Services Provided:

  • Specification of all DCS hardware and software
  • Review of all instrument and electrical equipment specifications.
  • Review of all design documentation from third-party engineering firm
  • Provide functional specification for batch and continuous control strategies
  • Continuous and batch configuration of DeltaV system
  • Operator display development
  • Conventional I/O, Foundation Fieldbus, ASi, Profibus
  • Electrical construction management
  • Operator DCS training
  • Onsite startup services
  • Control system: Emerson DeltaV

BASF: New High-Temperature Esterification Plant

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In order to increase its North American production of specialty esters, BASF (formerly Cognis Corporation) planned to build a new $14 million ester production facility in South Carolina. The centerpiece of this planned facility was a new high-temperature reactor and refining process. The reactor’s liquid ester product would then pass through a new $1.2 million automated pastillator to prepare for transport and bulk material handling systems.

CSA was brought in early on the project and handled project management, designing and installing all instrumentation and electrical equipment for the facility. We designed the layout of the new control room and wrote the specifications for all DCS hardware and software. We also wrote the specifications for all batch and continuous control strategies.

We configured the DeltaV system for batch and continuous control, developed and installed operator displays, and managed all electrical construction. And we provided operator DCS trainig.

When construction was complete, we handled on-site startup services. The new plant was completely successfully and to specification. Start-up went well, and the plant has greatly increased the company’s production.

Services Provided:

  • Project management
  • Design, specification, and integration services
  • Electrical construction management
  • Continuous and batch configuration of DeltaV system
  • Operator display development
  • Conventional I/O, Foundation Field bus, ASi, Profibus
  • Operator DCS Training
  • Control System: Emerson DeltaV

 

Millennium Specialty Chemicals: Migrating Distillation from APACS to DeltaV DCS

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Millennium Specialty Chemicals brought in CSA to upgrade the control system for their citronellol distillation column from APACS to DeltaV DCS.

We managed the entire migration, from design through configuration, testing, startup, and validation.

We developed the electrical and instrumentation design for the entire project. This included planning demolition of the existing APACS cabinet, designing and requisitioning the new DeltaV panel cabinet and the operator display, designing all conduit runs and the UPS power system, and providing terminal detail drawings for the electrical and instrumentation contractor.

For the new control system, we configured DeltaV Batch for a single-path train, recipe-driven, automated distillation process. We also configured DeltaV control and equipment modules, and configured conventional, Foundation Fieldbus, and ASi I/O points.

Prior to launch, we supported HFAT/SFAT, then managed startup and validation.

Our involvement at every step in the process meant we were able to plan for a smooth and trouble-free migration. The startup went well, and the new control and automation system has improved efficiency, throughput, and reliability at the facility.

Services Provided:

  • Configuration of DeltaV control and equipment modules
  • Configuration of DeltaV Batch for a single-path train
  • Configuration of conventional, Foundation Fieldbus, and ASi I/O types
  • Operator display development
  • HFAT/SFAT support services
  • On-site startup services
  • Provided layout drawings and bill of materials (BOM) for DeltaV panel cabinet
  • Requisitioned DeltaV panel build
  • Field-surveyed APACS cabinet prior to E&I design
  • Designed APACS demolition drawings
  • Provided terminal detail drawings for E&I installation contractor
  • Designed conduit runs from APACS cabinet to DeltaV cabinet, and associated conduit schedules, loop sheets, and system grounding drawings
  • Designed layout drawings and BOM for APACS cabinet conversion to DeltaV remote terminal cabinet. APACS I/O was demolished, and the existing loops were rewired into the DeltaV DCS
  • Designed and requisitioned UPS power system
  • HFAT/SFAT support services
  • Startup and Validation services
  • Control System: Emerson DeltaV

BASF: Ester Optimization

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BASF increased their ester production by 15% by converting an existing reactor with internal heating and cooling to an external heating and cooling reactor. They called on CSA to improve the heating and vacuum control of the reactor during the esterification process.

We wrote the functional requirement specification (FRS) and were the project manager for all design and installation of instrumentation and electrical equipment. We also developed instrument and electrical bid packages.

We converted the existing DCS from a Rosemount RS3 DCS to DeltaV DCS. And we programmed the new reactors with new temperature and pressure profile controls.

We provided on-site startup services, and stayed on the job until we’d tested and refined everything to our and BASF’s complete satisfaction.

Services Provided:

  • Project management of all design and installation of instrumentation and electrical equipment
  • Development of instrument and electrical bid packages
  • FRS of the batch configuration
  • Conversion of RS3 DCS code to DeltaV code
  • Continuous and batch configuration of DeltaV system
  • Operator display development
  • Conventional I/O, Ethernet I/O
  • Electrical construction management
  • On-site startup services
  • Control system: Emerson DeltaV

 

BASF: Ester Blending

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BASF calculated that they could save over $1.8 million per year by performing all lubricant blending operations in-house at their Ohio plant. They called on CSA to help them realize this savings.

We wrote the functional requirements specification (FRS) for the batch and pigging system, and we were the project manager for design and installation of all instrumentation and electrical equipment.

We installed a new automated pigging system and equipment along with new DeltaV DCS I/O to minimize contamination between products and to automate the lubricant recipe production. We automated transfer of the various blends to truck load-out, rail car load-out, and long-term storage tanks. And we integrated the pigging system with the blending batch operation.

To automate this intensive, recipe-drive process, we used S88 control & equipment modules, phases, operations, and unit procedures.

BASF was very pleased with our custom configuration and even more pleased with the annual savings.

Services Provided:

  • Project management for all design and installation of all instrumentation and electrical equipment
  • FRS of the batch and pigging system
  • Continuous and batch configuration of DeltaV system
  • Operator display development
  • Conventional I/O, Foundation Fieldbus, Ethernet I/O
  • Electrical construction management
  • On-site startup services
  • Control System: Emerson DeltaV

 

BASF: Meeting EPA Mandates with SIS Electrical and Controls Design

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In order to meet EPA safety requirements, BASF needed to install a regenerative thermal oxidizer (RTO) and an associated safety instrumented system (SIS) in their North Carolina plant. They called on CSA to design the control system and make mandated reporting easy.

We configured the DeltaV system to support the new RTO unit, and we also configured the SIS PLC programs and system. We designed the SIS PLC data to transfer to the DeltaV system via a DeltaV Serial Card utilizing Modbus protocol. We also configured serial communications from the AB SLC500 RTO PLC to DeltaV using a ProSoft Modbus card.

The EPA requires hourly reports of the RTO operation, so we installed our Easy Process Reporter software, which emails reports to the desktop of the responsible process engineer. Time schedule triggers as well as OPC DA data triggers fire off reports containing real time and historical data.

We made EPA-compliance easy for BASF, and they were very happy with the results.

Services Provided:

  • Configuration of DeltaV Control & Equipment Modules
  • Configuration of Conventional, Foundation Fieldbus, and ASi I/O types
  • Configuration of AB GuardPLC 2000 SIS PLC
  • SIS SIL Validation
  • Operator display development
  • SFAT On-site Startup Services
  • Onsite Startup support of the DeltaV and SIS systems
  • Configuration of CSA’s Easy Process Reporter software and utilized its OPC DA and OPC HDA for system report generation.
  • Control System: DeltaV and Allen Bradley GuardPLC 2000