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Energy / Petroleum Refining System Integration Project Profiles
Substation Control System Design and Integration
Project Management, Automation Engineering, Electrical Engineering, and System Integration was performed to deliver three networked substation control systems.
Eichleay Engineers Inc. was contracted by a San Francisco Bay Area refinery to provide automation engineering and turnkey software development for three new substation buildings and their associated 12KV, 4.16KV and 480V switchgear. Failure of this control system would disable the entire refinery, therefore control system redundancy and thorough written software testing was a requirement.
The following functionality was included in the final control system software:
- Control of three substation buildings and their associated Eaton overload relays, Schweitzer motor protection relays, Schweitzer transformer protection relays and Cutler Hammer VFDs.
- Data trending, data collection and reacceleration for over 300 motors.
- Integration with Honeywell TDC 3000 DCS, Triconex Safety Instrumented Systems and skidded PLCs
To deliver a turnkey system software implementation the following services were performed:
- Developed control panel drawings for dual redundant GE Rx7i PLC cabinets
- Designed plant-wide fiber optic network
- Coordinated design with skid vendors and reviewed skid vendor submittals as a client representative.
- Developed detailed automation functional specification documentation for the three substations
- Completed detailed network design, configuration and programming for DeviceNet, Ethernet, SEL Mirrored Bits and Modbus RTU.
- Performed software development for six redundant hot backup GE Rx7i PLC with Rx3i remote IO
- Performed GE Cimplicity 7.5 SCADA programming
- Developed test plan
- Wrote and ran Factory Acceptance Test (FAT)
- Currently performing Startup
- Currently performing Site Acceptance Test (SAT)
API Oil Water Separator Project
Project Management, Process Engineering, Electrical Engineering, Instrumentation Engineering, Automation Engineering, and System Integration was performed to provide a new turnkey control system for two existing API oil water separators.
Eichleay Engineers Inc. was contracted by a California based oil and gas company to upgrade two API separators used to treat refinery wastewater before discharge. The following project goals were met:
- Collect hazardous vapor off the top of separators, heat above dew point and send through six (6) carbon vessels to adsorb VOC contaminants from the waste stream.
- Include / upgrade, blowers, H2S monitoring, lift pumps, overall level, oil water interface level and temperature controls.
To deliver complete "preliminary", "issued for permit", and "issued for construction" design packages, the following services were performed:
- Developed P&IDs, performed hydraulic calculations for new systems.
- Sized carbon beds, blowers, heat exchangers and other miscellaneous process equipment for two vapor collection skids.
- Completed foundation, piping support and equipment support design and seismic calculations for two new vapor collection skids.
- Completed electrical design and single line drawings for new and upgraded motors, lighting and instrumentation power.
- Completed detailed piping design for fabrication of piping assemblies.
To deliver a complete turnkey control system for the existing two (2) API separators and two (2) new vapor collection skids the following services and materials were provided:
- Completed detailed control panel, DH+/fiber optic network design, instrumentation specification, and software specification for the new systems.
- Perform Allen Bradley PLC and PanelView HMI programming on three (3) networked PLCs and three (3) PanelViews.
- Supplied two (2) local PLC/HMI control panels, two (2) fiber termination panels, and miscellaneous field termination panels.
- Modified control room HMI to allow remote monitoring of the two separator systems.
- Attended weekly construction meetings and verified correct installation of the new control system components.
- Performed operator training and startup services to deliver a turnkey control system and provided operator manual.
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