On behalf of a longstanding client in the oil & gas downstream market, MSB’s Instrumentation & Controls division delivered process design, detailed engineering, project engineering and project management services for a Liquified Petroleum Gas (LPG) rail-unloading facility construction project at a New Orleans area refinery. The project expands the refinery’s product distribution by converting industrial greenfield land into a fully-commissioned LPG rail terminal with four railcar loading/unloading towers designed for future vapor recovery capability. MSB’s team of engineers and designers assisted in developing the feasibility study, FEED analysis and cost estimates to evaluate the practicality of the construction. MSB also delivered detailed design, equipment and materials specification, FAT execution, installation/construction support, and start-up and commissioning services. To meet the ambitious construction timeline, MSB provided staged design package deliverables while construction was underway. MSB also tapped its team of seasoned engineers midway through the project to re-engineer the LPG railcar skid vendor’s automation controls from a multi-PLC simplex design to a single TMR Fault Tolerant alternative. Completed in 11 months, the project was successfully delivered on time and within budget.
MSB has been providing engineering for substation maintenance and repairs for more than 40 years and brings extensive resources and experience to the construction of new facilities from the ground up. Working with a leading integrated downstream energy company, MSB managed the facility’s new unit substation replacement program from inception to startup and commissioning.
MSB provided custom-engineered and -designed work packages to meet the needs of the client’s particular infrastructure and construction requirements. MSB delivered a complete engineering package including feasibility and FEED studies; project planning and scoping; equipment specifications andvendor coordination; project management; detailed construction packages and startup support. MSB managed schedules and equipment delivery, as well as supported contractors performing load cutovers and grounding systems, control building, wiring and battery system installation. The new system will reduce outages, increase energy efficiency and lower operating costs at the plant for years to come.
MSB developed a strategy and corresponding design to upgrade existing process systems to allow for online testing of critical instrumentation and shutdown devices, thereby increasing the total availability of the systems involved. This project involved TIOT (Testing Interval Optimization Tool), evaluating all critical devices to determine testing intervals to achieve the desired availability targets. Piping and mechanical systems were then modified, as well as existing PLC programs, to allow online testing of all critical instrumentation and shutdown devices whose testing intervals were shorter than the planned units Turn Around.
MSB was hired to plan, design and implement a plant wide upgrade of existing storage tank level instrumentation systems. Over multiple project phases, MSB upgraded twelve storage tanks. The system transmits measured tank data such as levels, temperatures, and pressures, over a dual redundant wireless link and a fiber backhaul to the plant’s DCS and Tank Gauging Management System.
MSB developed a control system strategy to control two flood gates which were part of the Inner Harbor Navigation Canal Hurricane Protection Barrier that provided protection for the City of New Orleans and surrounding areas. MSB implemented the control strategy in the form of a PLC-based control system, along with Human Machine Interface terminals, which allowed operation from three separate remote locations.
A Gulf South gas distribution plant hired MSB to develop a PLC based control system to interface to a Smart MCC via Modbus TCP/IP, processing and sending the system information to the natural gas processing plant’s DCS system. This design created a central location within the control room for operators to view all relevant information from the MCC, such as current motor/pump loading, as well as the ability to control the MCC remotely. The PLC also provided shutdown protection, valve control, and motor control. MSB Electrical Power Department designed the MCC building, foundations and all interconnects to the existing sub-systems. MSB Instrumentation and Controls designed and implemented the PLC based control system.
MSB developed a complete construction package and cost estimate to relocate a gas processing plant’s Control System Console and DCS to an area outside of the plant’s potential blast zone. The project involved the dis-assembly, relocation, and re-connection of each control console, while maintaining online operation of the plant.