DCS System Upgrade – Light Ends Unit

Industry: Refining

Location: Baton Rouge, Louisiana

Client Benefits: Upgraded DCS System and Improved Operational Reliability

Project Drivers & Client Challenges:
The client had a legacy control system and needed to take advantage of modern technology to increase operational reliability by replacing an old Foxboro DCS system with a more modern Honeywell TDC-3000 DCS in their Light Ends unit.

Burrow Global Scope of Supply:

  • Detail Engineering Design
  • Construction Support & Startup
  • Procurement
  • I&E Disciplines
  • In summary this project installed a 3,300 sq ft Blast Resistant RIE, 26 HPMs, three PLC systems and transferred 6,786 loops.

Scope Description:
Burrow Global provided FEED and Detailed Engineering design for the replacement of a legacy Foxboro Spec-200 system with Honeywell TDC-3000 equipment in the Light Ends Unit.

Burrow Global developed the Project Design Basis (PDB) and subsequently detailed engineering, which included IFA, IFB and IFC drawing packages, INtools diagrams and wiring reports, engineering calculations, equipment specifications and procurement. P&IDs were updated to reflect new symbology. Remote Instrument Enclosures (RIEs) were designed to house new Honeywell equipment and included redundant UPS and HVAC systems.

The work scope also included equipment and construction bid analysis, construction support and start-up services. Burrow Global developed and executed detailed equipment FAT and SAT procedures as well as hot-cutover procedures for all loops Safety critical alarms were separated from DCS process alarms and we developed system architecture layouts for three critical PLC systems.

Project utilized EPCM Man-hours: 101,000 and was executed without incident.

Key Words:
DCS System Upgrade, FEED, Engineering, Construction Start-up