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Control Systems Upgrade for Major US Refinery

A major US refinery required control system upgrades as a result of hurricane damage as well as to minimise operational disruption from future weather events.

Client:

Confidential

Location:

Onshore, United States

Project Scope:

Control system upgradesThe project scope involved the upgrade of the existing control system, including full cutover to a new, flood-resistant replacement control building in order to minimise operational disruptions from flooding and to locate control operations outside the refinery process block.

A major hurricane severely flooded the refinery and control building located in the refinery process block. Due to the lack of field instrumentation documentation that was lost during the storm and inadequate scope/schedule development from a previous automation contractor, the client experienced serious cost and schedule variations compared to original project budgets.

The susceptibility of the existing control building to flooding created an urgent need to cutover to newer systems located outside the flood prone areas.

To meet the client's needs, Mustang:

  • Customised staff and plans to meet the refinery's specific and unique project constraints.
  • Assisted with project planning and customised project strategies to meet schedule and scope objectives.
  • Initiated an in-depth front-end engineering and design ("FEED") field instrumentation and system investigation and survey to establish a project basis, budget and schedule.
  • Continued monitoring the project relative to established objectives to maintain the original scope and design basis.
  • Executed detailed design, system configuration and commissioning services to support hot cutover.

Client Benefits:

  • Mustang's flexibility allowed the project to be customised to the specific operations and plant resource constraints.
  • The team's technical expertise and years of cutover experience identified undocumented issues early in the project, which enabled effective cutover of the existing system.
  • Mustang's efficient field survey, project scoping, project management and detailed design execution capabilities resulted in completing the control system upgrade project within budget.