Executive Summary
Chevron, Cape Town, South Africa
Chevron entered the South African market in 1911 and now markets its products there under the Caltex brand, which was created in 1936 by a joint venture between Standard Oil of California (the present Chevron) and The Texas Company (Texaco). Chevron operates a 100,000 barrel-per-day refinery in Cape Town that produces gasoline, diesel, jet fuel, LPG, and asphalt.
Chevron South Africa initiated a project to replace the existing Yokogawa CENTUM-XL process control system at the Cape Town refinery with CENTUM CS 3000 hardware and upgrade the control network to Vnet/IP.
Project Background
This project had the overall aim of ensuring the high reliability and availability of the refinery's distributed control system (DCS). The existing CENTUM-XL control system had been in use for over 15 years, leading to concerns about the rising risk of unplanned plant shutdowns and production losses as well as increased maintenance costs.
The intent was to replace the existing CENTUM-XL control stations with the latest Yokogawa CS 3000 hardware and upgrade the control network to the faster and more efficient Vnet/IP. In June 2008, Yokogawa South Africa was appointed principal contractor and given overall responsibility for the project.
Project Overview
The plan was to minimize plant downtime by doing a hot cutover from the old to the new control system, and to then immediately test all instruments and controls.
Structured and formal project and engineering procedures were developed to make sure that every process requirement would be fulfilled and all risks mitigated. The execution procedure culminated with a thorough risk assessment process that involved all key stakeholders.
To meet all of Chevron's requirements, personnel responsible for reliability and maintenance, advanced control, construction, and operations were assigned to the project.
Prior to the hot cutover of each control station, the existing system was re-configured for the CS 3000. A formal process was followed to ensure all the control logic and functionality was retained and that this complied with the software configuration standard developed for the project.
After the approval of the design, the Yokogawa CS 3000 hardware was installed in the DCS panels and the panels were acceptance tested.
The hot cutover process was carried out on an individual I/O point basis. Field wiring was transferred point by point from the old DCS to the new DCS and at the same time the existing configuration (program) was disabled and the new configuration activated. Control valves were bypassed until the controller was successfully cut over.
Success Factors
The cutover of this 100,000 barrel-per-day Cape Town refinery was performed live without disruption to production operations, and Yokogawa achieved this on time and within budget.
The following key factors contributed to this success:
- The experience of the team members
- Excellent teamwork between the Yokogawa and Chevron personnel assigned to the project
- Good communication between team members during the cutover process
- The planning and implementation of a structured and methodical approach
- The completion of a thorough risk assessment process to mitigate all risks
- Continual evaluation and improvement of processes based on lessons learned
Customer Satisfaction
Comment from Phillip Venter – Project Manager "There are several factors that I believe were major contributors to the success of this project. From the RFQ stage of the project there was excellent teamwork between Yokogawa and Chevron. We all shared the vision of successfully completing the project within schedule and budget, with no production loss and zero incidents.
Having the entire Yokogawa team in one location on site has drastically improved the efficiency of the team, coupled with each team member's personal commitment to the project. It sure has been a pleasure and an honor to work with the Yokogawa project team.
In any project, strength lies in the ability to adapt to the ever changing circumstances and the collective effort of continuous improvement."
Phillip Venter, Chevron
Project Statistics
Control system upgraded to CENTUM CS 3000 Vnet/IP
Hardwired I/O cut over: | 7,132 |
---|---|
FCS's cut over: | 24 |
I/O modules: | 611 |
Nodes: | 123 |
System cables: | 805 |
Terminal boards: | 499 |
Domains upgraded to Vnet/IP: | 3 |
Engineering stations (EWS): | 3 |
Human interface stations (HIS): | 30 |
Incident free man-hours on site to date: | 50,584 |
Number of loss incidents: | 0 |
產業別
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石油和天然氣下游
近年來,石油和天然氣下游產業面臨著越來越多的挑戰。這些挑戰包括待加工原料的特性變化、工業設施及設備的老化、能源成本的上升、缺乏能夠使煉油廠安全有效運行的熟練技術工人,以及市場和客戶的需求不斷變化。
多年來,橫河與許多下游公司合作,致力於提供應對這些挑戰和問題的工業解決方案。橫河的解決方案幫助工廠投資者盡可能實現最大的盈利能力和工廠內可持續的安全。 -
精煉
在不斷變化的市場中,煉油廠不僅是原油加工單位,而且是利潤中心。同時,人們強烈意識到煉油廠設施安全性的重要。為了實現盈利,效率及環境保護的長期目標,需要包括計劃,調度,管理和控制的總體生產解決方案。憑藉在自動化領域多年積累的專業知識,橫河可以為您提供經濟實惠的完善的整體解決方案,改善操作並使世界更清潔。
相關產品&解決方案
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切換規劃和實施
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分散式控制系統(DCS)
我們的分散式控制系統 (DCS) 可自動化和控制製程,提高績效。 已經超過 10,000 家工廠利用Yokogawa DCS 實現生產目標。