Extraction Plant Modernization

INDUSTRIES
  • Oil & Gas
SERVICES
  • PLC-5 Migrations
  • Training
  • Project Management
  • PLC
  • Electrical Design
  • Detailed Engineering
  • Controls Commissioning Services
  • Control System Migration
TECHNOLOGIES
  • PLC-5 Migrations
  • Training
  • Project Management
  • PLC
  • Electrical Design
  • Detailed Engineering
  • Controls Commissioning Services
  • Control System Migration

The Challenge

The client operates a deep cut extraction plant located in Northeastern British Columbia.  The plant was originally commissioned in 1985 and has a licensed natural gas processing capacity of 750 Mmcf/d. The plant was running Allen Bradley PLC-5s and was looking to migrate the existing PLC controls to a new Allen Bradley ControlLogix PLC platform.  The current hardware installation included over 150 PLC I/O cards spread over 16 PLC racks and was anticipated to become obsolete in the coming years.

In order to accomplish this amount of I/O to be migrated within the allotted time frame, the use of a new Rockwell Automation RSLogix 5000 translation tool was needed to be tested and implemented.  The project also used the relatively new Rockwell PLC I/O Conversion Modules for 1771 I/O which virtually eliminated the rewiring process and minimized downtime as there was no need to re-commission each end device.

Autopro's Role

As the site's preferred automation systems consultant, Autopro was initially tasked with the responsibility of migrating the existing PLC platform to the new ControlLogix PLC.  This scope included the electrical design for new hardware installation as well as modifications to the software system.

During the execution of this project, the turnaround schedule was the key success criteria, and startup happening on schedule was absolutely critical, a deadline which Autopro personnel succeeded in delivering on. 

Autopro’s responsibilities included:

  • Overall project management
  • Electrical detailed engineering
  • Customer acceptance testing
  • Software development and implementation
  • Controls check out and commissioning
  • Operations training
  • Startup support

Success Criteria

  • Schedule- Met clients shutdown date
  • Successful use of new translation tool
  • No additional downtime beyond scheduled 12 day plant outage
  • Budget- Completed project within acceptable tolerances (+/- 10%)

Project Metrics

Project Completion Date