Key Achievements
- Near elimination of hardware failures, greatly enhancing reliability.
- 35% reduction in operational and maintenance costs.
- Project delivered 5% under budget.
- Transition towards unmanned operations, allowing for real-time remote facility management.
Project Overview
This project involved a comprehensive upgrade of automation and control systems at a key gas processing facility. The project included the design, engineering, implementation, and commissioning of upgrades to instrumentation, safety controls, PLCs, remote I/O racks, flow computers, and communication links, including a significant fiber network. A major enhancement was the introduction of fully automated dehydration tower switching valves for five towers, paired with advanced virtualization for enhanced operational control and monitoring. These strategic improvements not only boosted operational reliability but also ensured compliance with current safety and regulatory standards, positioning the facility for future efficiencies and continuous production.
The Challenge
Prior to the upgrade, the facility faced frequent hardware failures causing operational disruptions and productivity losses. The lack of support for outdated hardware and software further exacerbated the situation. The facility’s operations were severely hampered, with maintenance teams burdened with keeping systems running minimally and inefficiently.
Located in a remote area, the facility’s accessibility issues compounded the challenges, particularly during adverse weather conditions. The environment demanded robust systems capable of withstanding severe conditions.
The project not only focused on technological upgrades but also ensured compliance with stringent safety and environmental regulations, crucial for maintaining operational licenses and avoiding penalties.
Our Solution
Our team implemented a robust set of upgrades using Rockwell ControlLogix processors (Redundant) and I/O, remote I/O panels tailored for Class 2 conditions, and PlantPax virtual machines running on Stratix fault-tolerant servers. Security enhancements were thorough, ensuring controlled access and secure remote operation capabilities. Communication upgrades included new ethernet links over radio and a local fiber network forming a redundant ring for reliable data transfer. The dehydration system was completely automated with new valve operators, and digital replacements were made for outdated pneumatic indicators. All fire and gas detectors were also upgraded to the latest models.
Key Results
- Reduction of Hardware Failures: Virtually eliminated, enhancing system reliability.
- Supported Software and Applications: All systems were updated to be fully supported, streamlining maintenance.
- Operational Ease: Simplified operations contributed to reduced direct management needs.
These strategic upgrades enabled the facility to transition towards more unmanned operations, facilitating remote management from any location, enhancing flexibility and responsiveness.
A 35% cost reduction was achieved in maintenance and operations, with the project finishing 5% under the initially projected budget due to strategic efficiencies in project design and execution.
Looking Ahead
The strategic upgrades at the facility are expected to deliver long-term operational efficiencies and cost savings. Maintaining such high standards in functional and security performance will require periodic updates, roughly every 5-7 years, to adapt to evolving technological and security landscapes.
The success of this project can be attributed to a blend of comprehensive expertise, our previous project experience, and a deep understanding of the client’s operational needs. This combination allowed us to navigate complex challenges effectively and deliver solutions that exceeded expectations.
Partner with Catch Engineering for your next project to achieve engineering excellence. Contact us today to learn how our expertise can help you achieve your project goals.
