DCS System Upgrade

Industry: Refining

Location: Baton Rouge, Louisiana

Client Benefits: Increased 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.
Burrow Global Scope of Supply:

  • Detail Engineering Design
  • Civil/Structural
  • Procurement
  • I&E Disciplines

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.

Burrow Global’s work included development of the Project Design Basis (PDB) and execution of detailed engineering. Detailed engineering generated two formalized drawing review sessions in addition to IFA, IFB and IFC drawing packages. INtools diagrams and wiring reports, engineering calculations, equipment specifications and procurement were also included. P&IDs were updated to reflect new symbology.

The new equipment, including six (6) controllers, was installed in a previously designed and constructed remote instrument enclosure (RIE). The scope of work also included equipment and construction bid analyses, 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 as part of the design requirement. The architecture for three (3) critical PLC systems was developed. Major fiber optic cable runs were designed and successfully installed and tested. This project transferred 2,573 loops, which included 300 control valves.

Project utilized EPCM Man-hours: 58,716 and the project was executed without incident.

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