DCS System Upgrade – Coker Unit

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 in their coker unit.
Burrow Global Scope of Supply:

  • Detail Engineering Design
  • Construction Support & Startup
  • Procurement
  • I&E Disciplines
  • The deliverables included the design for a 1,530 sq. ft. blast–resistant RIE, eight HPM’s, marshaling panels, more than 2 miles of diverse fiber optic cables and two fully equipped satellite houses to accommodate specific field signals. The hot-cutover team transferred 2,664 loops to the new DCS system. Approximately 320 control valves were transferred during hot-cutover.

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 Coker Unit.

Burrow Global’s work included development of the Project Design Basis (PDB) and subsequently detailed engineering for 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 Honeywell equipment and included redundant UPS and HVAC systems.

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. We developed system architecture layouts for three critical PLC systems and performed associated SIL calculations. PLC FAT and SAT procedures were developed and executed.

Project utilized EPCM Man-hours: 49,393 and was executed without incident.

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