case study: fire & gas expansion

CASE STUDY: Fire & Gas Expansion

BENEFITS | High Reliability & Availability | Safety Risk Reduction | System Data Historical Logging & Archiving | | Dynamic Trending Functionality | Enhanced Data Connectivity | Effective Alarm Management |

CHALLENGEOur customer were undertaking a field development project to increase the capacity of their gas handling facilities in their field development.

Bilfinger UK were awarded a contract to expand approximately 70 MMSCFD of low pressure (LP) compression at a LP compressor station and 70 MMSCFD of high pressure (HP) compression at a HP compressor station in the field, along with additional pipelines.

SOLUTION• We provided a process control system

and Safety Integrity Level 2 (SIL2) safety system for their fire and gas system.

• We designed, developed, implemented, installed and commissioned the control system in compliance with the customer’s rigorous standards.

Technical Information Summary

TECHNOLOGY USED

• SCADA/HMI – Iconics Genesis32 and FTView ME.

• PLC – Rockwell ControlLogix.

• Functional Safety – SIL2 rated ESD system.

• Historian/MES – Kepware OPC server interface to enable access to MES system.

• Communications – DeviceNet, Modbus and OPC configuration.

• Bespoke Software – Alarm handshaking functionality between FTView and Iconics AlarmWorX and DataWorX.

• Others – UPS design and provision.

• Management – Full project life cycle using our ISO 9001 TickITplus accredited quality management system.

• Panels – Control panels.

CASE STUDY: Gas Field Development

BENEFITS | High Reliability & Availability | Hierarchical Alarm Management & Prioritisation || SIL3 Risk Reduction | Extensive Trending of Key Process Variables | Sustainability by Design |

CHALLENGEOur customer required development of their gas field to expand their operations.

The process involved gas being extracted from the underground gas well and the pressure being reduced before it is treated with methanol to avoid potential blockages in the line. Gas is then transferred to a gas processing area and then superheated before passing to the gas turbine tie-in.

Bilfinger UK were awarded a contract to increase the availability and safety of this process, which was critical to the customer’s operations.

SOLUTION• We supplied a high availability control

and safety system based on a Siemens S7-400 FH, which covered the process, a Safety Integrity Level 3 (SIL3) rated fire and gas system and a emergency shutdown system.

• We integrated the solution into the CCTV monitoring system at the well head, HMI and telecommunications systems.

• We provided extensive consultation to the customer while developing the design of the complete solution.


TECHNOLOGY USED

• PLC – Siemens S7-400FH.

• Functional Safety – SIL3 rated F&G and ESD system.

• Historian/MES – Metering reporting.

• Communications – Profinet.

• Others – CCTV monitoring at well head to assist operators.



CASE STUDY: Phase 2 Upgrade

BENEFITS | Entire Site Single Design Authority | Consistent Application of Design Standards | | Effective Planning & Co-ordination | Reduced Maintenance Costs |

CHALLENGEOur customer required a phase 2 upgrade of their aluminium smelter in Abu-Dhabi, which consisted of building a complete new smelter adjacent to the existing smelter to double production capabilities.

The expansion involved the use of a wide range of equipment from various OEMs around the world with no common standards or defined interfaces.

Bilfinger UK were awarded a contract to effectively manage the project risks to ensure it was a success.

SOLUTION• We provided engineering consultancy

and managed the delivery of the OEM control systems.

• We supplied technical support and guidance to the customer and OEM vendors.

• We ensured that all of the automation and networking elements met the customer’s standards, adhered to best practice guidelines and that all of systems were delivered on time.


TECHNOLOGY USED

• SCADA/HMI – FTView SE/ME.


• Historian/MES – FT Historian, also fully validated and verified MES data and reports.

• Communications – DeviceNet, ControlNet and OPC configuration.

• Networks – Sitewide Hirschmann configuration including VLan creation, Firewall configuration and fibre optic testing.

• Bespoke Software – VBA and SQL script development to enhance functionality including alarm management screen.

• Others – Sitewide FT Asset Centre configuration, training of operations team in use and maintenance of automation systems.

• Management – Planning and coordination of site works involving multiple vendors.

CASE STUDY: Clean Room Monitoring & Control

BENEFITS | GAMP Standard Delivered | Compliance with CFR21 Part 11 Regulations | Existing Systems Integration | | Designed for Future Expansion | Effective Monitoring & Control of Clean Room Conditions |

CHALLENGEOur customer’s control system provided monitoring and control of cell culture processes, which are used to provide active ingredients for vaccinations.

The control system monitored and controlled a number of conditions including; temperature, humidity, atmospheric pressure, airflow and oxygen.

Bilfinger UK were awarded a contract to implement equipment to monitor and control the environment within the clean room, which is critical as even the slightest variation in temperature could significantly affect the process.

SOLUTION• We carried out the detailed design,

programming, installation and commissioning of a validated automation system for the environmental monitoring and HVAC equipment in the manufacturing bioprocess utilising a Siemens PCS7 DCS.

• We delivered the system using Good Automated Manufacturing Practice (GAMP).

• We provided a foundation for future expansion and replacement of obsolete automation systems.


TECHNOLOGY USED

• SCADA/HMI – Siemens PCS7.

• PLC – Siemens S7.

• Networks – Wireless communications.

• Others – Tablet PCs were used as SCADA clients.

• Management – GAMP, CFR21 Part 11 and full project life cycle using our ISO 9001 TickITplus accredited quality management system.

CASE STUDY: Production Improvements

BENEFITS | Integration of 30 Different Control Systems | Increased Data Availability & Asset Monitoring | | Production Transparency | Improved Production Performance | Waste, Cost & Energy Use Reduction |

CHALLENGEOur customer were one of the largest producers of dairy producers in the UK, producing 2.2 billion litres of milk every year.

As part of their ongoing expansions a new pre-pack facility was needed to improve quality, reduce costs and provide environmental sustainability.

Bilfinger UK were awarded a contract to develop and install a factory wide SCADA, historian and MIS system for the customer’s new facility.

SOLUTION• We designed the system using a

Wonderware System Platform with additional equipment performance and operations modules.

• We provided effective reporting using a Wonderware Historian and MES to deliver greater transparency of the facility’s data and the tools to enable the customer complete their operations more efficiently.


TECHNOLOGY USED

• SCADA/HMI – Wonderware System Platform.

• Historian/MES – Wonderware Historian and Wonderware MIS.

• Communications – Ethernet.

• Others – Equipment performance and equipment operations modules.


CASE STUDY: Export Control & Monitoring

BENEFITS | Implementation of a Full Site Simulation Environment | Increased Waste Storage Time | | Effective Nuclear Waste Move, Track & Store Sequences | SCADA System KPI Monitoring & Reporting Integration |

CHALLENGEOur customer had a number of ponds, which were used to safely store nuclear waste for short periods of time.

These storage ponds were not suitable for long term storage so as part of the decommissioning activities this nuclear waste had to be moved into long term storage solutions, which had associated risks such as hydrogen build up.

Bilfinger UK were awarded a contract to provide a solution to resolve this issue and to effectively manage the waste thereafter.

SOLUTION• We designed and implemented the

control system using a WonderwareSystem Platform, a Rockwell ControlLogix PLC and plant simulation software.

• We included waste agitation within the control system to avoid the potential of hydrogen building up and becoming a hazard.


TECHNOLOGY USED

• SCADA/HMI – Wonderware System Platform.


• Historian/MES – Wonderware Historian.

• Communications – Profibus , Modbus TCP/IP, ControlNet, Ethernet and OPC.

• Networks – Hirschmann, fibre optic and ethernet.

• Bespoke Software – VB/VBA and enhanced functionality (prompts and sequences).

• Others – PICS simulation and full site simulation development system.

• Management – Strict customer requirements and standards.

• Panels – Server, marshalling and PLC panels.

CASE STUDY: Energy Monitoring System

BENEFITS | Savings of £200K | Independent Evaluation of Enterprise Energy Management Products | | Energy Monitoring System Deployment | Building Monitoring & Reporting |

CHALLENGEOur customer required an effective energy monitoring solution for their building management as part of their sustainable green initiatives.

As the customer’s building was multi-tenanted, they needed a solution to provide a clearer insight into their buildings energy use to save energy.

Bilfinger UK were awarded a contract to provide a solution that would accurately measure and record data, to ensure the customer met their carbon reduction requirements and could bill accurately.

SOLUTION• We implemented an energy

monitoring system after working closely with the customer to understand, consult and agree their specifications.

• We provided a unified open web interface for the BMS, LMS, HVAC, CCTV and electrical systems with robust security features to protect their sensitive data.


TECHNOLOGY USED

• Historian/MES – Energy management software.

• Communications – Ethernet.

• Others – Schneider Electric energy meters.

• Management – Consultancy and scope definition.

CASE STUDY: Control System Refurbishment

BENEFITS | Modernised Control System | Upgraded Control & Diagnostics | Greater Reliability & Maintainability || Flexibility for Future Enhancements | Increased Data Availability | Improved Remote Communications |

CHALLENGEOur customer required a replacement of their Hydroelectric Control Scheme at apower station in North Wales.

The Grade II listed building houses one of the oldest grid connected hydro-electric stations in the world, which, after several upgrades in its history, now contributes almost 10 megawatts of electricity to the grid.

Bilfinger UK were awarded a contract to complete this replacement using automation solutions.

SOLUTION• We replaced the unit control PLC,

electrical panels and MCC.

• We provided a new local Human Machine Interface (HMI) and the SCADA system interface.

• We replaced the control panels for the turbine governor and the generator’s Automatic Voltage Regulation (AVR).


TECHNOLOGY USED:

• SCADA/HMI – Rockwell FTView SE/ME.


• Historian/MES – Rockwell Historian.

• Communications – DNP3 communications via satellite.



CASE STUDY: Control System & ESD Upgrade

BENEFITS | Minimised Site Equipment Downtime While Commissioning | Greater Control of System || Modernised Control System Code | Improved Overall System Reliability |

CHALLENGEOur customer site’s main function is to receive two grades of condensate product from the gas processing facility via a pipeline and to then load these grades safely onto rail cars for export without mixing them.

The site required modifications to the Basic Process Control Software (BPCS) and Safety Instrumented System Software (SIS) to ensure the recommendations of the HAZOP and LOPA reports were adopted.

Bilfinger UK were awarded the contract to design and implement the EC&I and automation required to meet these requirements.

SOLUTION• We delivered a complete solution for

our customer; including replacement of control panels, site installation and replacement of 12 legacy ESD systems with SIL2 rated safety PLCs.

• We developed an innovative changeover strategy to keep pipelines operational throughout install and commissioning phases.

• We continue to support our customer with a 24/7/365 service support contract.


TECHNOLOGY USED:

• PLC – Allen Bradley ControlLogix and GuardLogix.

• Functional Safety – Control system configured to IEC61151.

• Communications – Ethernet/IP, ControlNet and Modbus TCP/IP.

• Networks – Fibre optic.


• Panels – Control panels and retrofit of ESD package.

• Others – Installation and Commissioning.

CASE STUDY: Nuclear Waste Effluent Treatment Project

BENEFITS | Removing Obsolescence | Enhancing Operations | Enhancing Supportability | Secure by Design | | Improved Data Connectivity | High Reliability & Availability |

CHALLENGEOur customer required a cyber secure control system upgrade as part of their control system expansion.

They needed to integrate their cybersecurity life cycle process into a traditional control system design to address many cyber related risks such as obsolescence and supportability, system availability, integrity and confidentiality, secure operational technology application design and secure operational technology infrastructure.

Bilfinger UK were awarded the contract to deliver the control system upgrade and cybersecurity solution.

SOLUTION• We executed the cybersecurity life cycle

process in-line with IEC62443, to ensure the appropriate assessment of cyber risks and implementation of chosen technologies according to risk was implemented.

• We leveraged Microsoft Windows security technologies as part of the solution and provided patch management and a secure network infrastructure.

• We provided an integrated Network Monitoring System (NMS) to monitorand report on functions.


TECHNOLOGY USED:

• SCADA/HMI – Archestra 2014, ESXi Server 2012 R2 VMs and FTView ME.

• PLC – ControlLogix PLCs.

• Cisco IDS – FirePower System V6.4.

• Networks – Cisco/Rockwell Network Devices IE4000/Stratix and EthernetVirtual LANs.


• Panels – Server and PLC panels.

case study: fire & gas expansion

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