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November 21, 2008 |
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| Title: |
| Transmix Processing Unit |
| Location: |
| Greensboro, NC |
| YEAR COMPLETED: |
| 2007 |
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| Project Description: |
With the upcoming introduction of the ultra low sulfur diesel, there was a need to deal with the increase volume of transmix fuel that would soon follow. Arseal was involved in a project to help one of our client’s capitalized of reprocessing the transmix back into fuel,
diesel, or gasoline. By reprocessing the transmix back into useable refine products, the client can sell the reprocessed products that would otherwise have been lost. The company would also save money in the transportation cost of shipping the transmix to reprocessing companies.
We worked closely with the client to develop an automation & control system that would monitor and control the activities of the transmix reprocessing unit to maintain the safety and reliability of the system at all times. Due to the extreme high temperatures, safety of the equipment and personnel was always
the primary concern when designing the operation and control of the system. The automated control system consisted of the following:
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- (2) iFIX SCADA/HMI Server Nodes
- iFIX SCADA/HMI Client Node located in the QA Lab Room
- Allen-Bradley SLC Programmable Logic Controller
- Allen-Bradley Panelview 1400e Graphical User Interface
- (2) Allen-Bradley ControlLogix Programmable Logic Controller
- Heater Cooling Fan Baldor Drives
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The automation & control system utilized three SCADA/HMI node located at the Main Control Building, MCC Building, and QA Lab Room
(also located in the Main Control Building). The HMI/SCADA system was designed with a redundancy fail-over feature to keep the system
running even if one of the primary server units fails. An existing Allen-Bradley SLC PLC was modified to gather tank level indications
and alarms and send the data using a Prosoft Ethernet Communication module to one the Allen-Bradley ControlLogix PLCs located at the MCC Building.
An existing Allen-Bradley Panelview graphical user interface was modified to display the additional tank level information along with the tank
level alarms on a new screen. The communication link between the SLC and Panelview equipment was via a DH+ communication link. The SCADA/HMI
server nodes communicated with the two Allen-Bradley ControlLogix PLCs located at the remote MCC building. One PLC controlled the operations
of the transmix processing unit, while the other PLC controlled the operations between the pipeline and transmix facility as well interface with
the pipeline control center SCADA system via a Prosoft ModBus over TCP/IP communication module.
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| Services: |
- Project Management
- Program of Allen-Bradley SLC and ControlLogix Programmable Logic Controllers (PLC)
- Develop new screens into existing Allen-Bradley Panelview 1400e graphical user interface
- Develop SCADA/HMI system with redundant nodes using iFIX Proficy SCADA HMI/SCADA software version 4.0
- Configure Ethernet communications between programmable logic controller, graphical user interface, and HMI/SCADA system
- Configure ModBus over TCP/IP communications between Allen-Bradley Programmable Logic Controller and the client’s control center SCADA system
- System simulation, testing, and verification
- Design, fabrication, and assembly of two pre-fabricated PLC control cabinets
- System Specification and Design Construction Package
- Operation & Maintenance Manual Development
- Bid Construction Meetings
- Installation and Commissioning
- Post-commissioning Support
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| Standards Applied: |
- RP 500
- NEC 2005
- ANSI/ISA-S5.1-1986 (R1992)
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| Construction: |
| The construction phase of the project involved many activities that include: |
- Installation of Heater System
- Construction and fabrication of transmix processing unit
- Installation of new Motor Control Center building
- Control room remodeling
- Installation of pre-fabricated PLC cabinets
- Installation of fiber optic link between MCC building and Main Control Building
- Installation of fiber optic link between MCC building and Remote pipeline facility
- Installation of HMI/SCADA equipment and communications cabinet in the Main Control Building
- Electrical wiring to process control devices to the PLC
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