Client Goal

Business Goals:

• Obtain reliable, real-time information from Natural Gas infeed systems to maximize NG consumption cost efficiency
• Increase control system robustness and reliability
• Avoid any production downtime

Technical Goals:

• Convert existing Fisher Provox Control System to DeltaV
• Connect new DeltaV system with existing Foxboro, Historian (OSI PI), and SOE systems
• Collect and Analyze Gas Metering Data

Project Overview

Our Client owns a 1000 Megawatt Dual-Fuel (Steam & Gas) Power Plant located in Texas. Texas State Energy Industry Deregulation necessitated availability of reliable process data, and required the modernization and integration of obsoleting technologies. The existing architecture did not enable the Client to retrieve the data needed to operate the plant to deregulation requirements, and did not provide the data to the right places or people at the right time to enable them to operate the plant as effectively or efficiently as needed.

Tegron provided the migration of an existing Emerson Provox DCS to Delta V, and upgrade the control system LAN and network infrastructure needed to integrate disparate plant systems. The migrated DCS controlled the primary Natural Gas Transmission (Infeed) System, Gas Meters and Chromatographs, and associated Fieldbus Pressure, Temperature, and Flow Field Instrumentation. Following a comprehensive design, review and planning phase, the system was thoroughly simulated and Factory Acceptance Tested. The conversion done on the “live” system, with point-by-point conversion executed to detailed a Cutover Plan developed by Tegron directing Customer, Tegron, and Installation Trades personnel.

Scope of Supply

• Project Management
• Detailed Design and Documentation
• DCS Development
• Control Panel Assembly
• System Simulation
• Factory Acceptance Testing
• I&C Installation Supervision
• Site Acceptance Testing

The Outcome

• Complete conversion involving approximately 200 I/O was completed successfully in 16-hour window with 0 failures or impact to production
• Production process is robust, well defined, and integrated
• All real time production information appears where the Production Managers need it most
• System architecture is completely scaleable
• Increased isolation and mitigation of equipment failure
• Operations and Maintenance costs minimized