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Project Summaries and Case Studies
Every project has a unique set of challenges and objectives, including scope, budget, time frame, regulatory requirements and more. MAVERICK addresses each concern in developing custom solutions that meet each customer’s needs.
Chemicals and Petrochemical Projects
- Fertilizer Manufacturer Implements Plant-Wide Systems Integration Solution
A manufacturer of water-soluble fertilizer needed to integrate its plant floor controls with its
manufacturing execution system (MES) and enterprise resource planning (ERP) system to
improve production monitoring and optimize plant utilization.
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- Major Chemical Manufacturer Reduces Waste Disposal Costs through Advanced Process Control (APC)
Due to site-wide production rate increases from several process units, the organic waste streams
at a chemical plant had grown beyond the combustion capacity of its waste fuels boiler (WFB).
Waste that wasn’t burned in the WFB had to be shipped off-site for disposal at a significant
(per pound) cost to the business.
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- Advanced Process Control for a Refinery and Chemical Complex in Germany
A large global energy company operates an integrated, high-conversion refinery, an olefins plant and several petrochemical and chemical units at a single site near Cologne, Germany. The site has utilized Honeywell DCSs, first TDC 2000 and later TDC 3000. MAVERICK has implemented several major APC projects at this site, including projects on an aromatics complex which first distilled reformate for recovery of a C-8 heart cut and then processed this stream utilizing UOP’s Parex™ and Isomar™ processes to recover pure para and orthoxylene.
Another project implemented APC on a vacuum resid partial oxidation unit producing syngas, which was then reacted to form methanol. The most recent project implemented inferred properties and model-predictive control (utilizing RMPCT™) on a crude distillation unit and associated debutanizer for LPG recovery.
| 2002–03 |
Crude Distillation Unit (with Naphtha Splitter) APC Project implemented RMPCT controllers and inferred properties (TDC 3000) |
| 2002–03 |
Resid Gasification / MeOH Synthesis / H2 Production & Purification APC Project implemented APC (TDC 3000 AM) |
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- Advanced Process Control for Plastics Company in the U.S., the Netherlands and Spain
A global plastics company operates four large manufacturing facilities worldwide for the production of Lexan™, a versatile polycarbonate engineering plastic. Two of these plants are in the U.S., one is in the Netherlands and one is in Spain. Lexan is manufactured from Bisphenol-A (BPA) by polymerizing it with a carbonate-donating reactant, usually phosgene. MAVERICK has implemented APC in BPA units at all four sites. AspenTech’s DMCPlus™ was utilized as the APC platform for the unit in Spain. Post-project audits at two of the sites confirmed major measurable productivity improvements. MAVERICK has also implemented DMC controllers on other process units at the site in Spain. In that case, BPA is produced by an alternate route that eliminates phosgene as a reactant.
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- Automation Services and Expansion Project for Global Chemical Complex in the Netherlands
One of the world’s largest chemical companies operates its largest production site (26 production units) in the Netherlands. MAVERICK Technologies is providing full-time, experienced process automation professionals to support internal projects and ongoing initiatives at this location. Engineers are currently involved in an expansion project that will be adding a new production train and optimizing the transfer and storage of the final product. Engineers are also supporting furnace optimization to increase efficiency and total load that will allow more production train capacity.
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- Automation Engineering and DCS System for Lactic Acid Plant in Thailand
To capture the projected double-digit growth in lactic acids in Asia, a large company built a new plant in Thailand. The lactic acid and lactic acid derivatives market is expected to continue to grow by more than 10 percent annually in Thailand. The new plant will provide the company with a lactic acid capacity of 100,000 tons undiluted, and 15,000 tons for the sodium / potassium lactate.
MAVERICK Technologies’ Thailand partner, ZI-ARGUS Industrial Automation, is responsible for all the automation engineering and delivery of the distributed control system for the processing areas for this new production facility.
Deliverables include:
- DCS system hardware – the hardware components of the DCS, where applicable, completely assembled into suitable panels and pre-tested
- DCS system firmware licenses – the software licenses required for configuration, application engineering and operating and diagnosing the DCS system as part of normal plant operations
- Engineering services – the design, assembly, development and commissioning / startup of the DCS system
Anticipated completion date is Q1-2008.
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- Electrical Distribution Monitoring System in Singapore
A large global energy company selected an integrated petrochemicals construction project as an extension to its already major presence in Singapore.
MAVERICK has been selected to provide definition, design, programming, procurement, installation and startup support services for the project's electrical data monitoring system (EDMS). There are 24 substations and two gas turbine generators that will be monitored for approximately 30,000 tags. MAVERICK will be implementing a CIMPLICITY architecture, including integration with the primary plant control system based on the Honeywell Experion PKS platform.
MAVERICK will be implementing a CIMPLICITY strategy for the EDMS system using CIMPLICITY v. 7.0 to include:
- ProServer no-limit development and runtime system
- Host redundancy option
- OPC server
- WebView 10-pack
- Modbus TCP / IP communications driver
- Viewer runtime system, with one year of Global Care
- Viewer development and runtime system, with one year of Global Care
- Server no-limit runtime system, with one year of Global Care
- ProServer 75 I/O development and runtime system, with Proficy GlobalCare
There will also be six communication servers that will interrogate the field devices via Modbus TCP / IP. The communication servers will have dual fiber—optic ports and will be connected to a fiber—optic patch panel located inside the automation control building (ACB). The data collected will be served up to OPC servers.
An EPKS Gateway consisting of two routers will be provided to allow engineering access to the network. This gateway serves as an entry point into the network for the Honeywell DCS and will utilize the Hot Standby Routing Protocol (HSRP) for redundancy. Furthermore, a satellite clock will be provided to time-synchronize the PC equipment in the ACB using the network time protocol (NTP).
The engineering room houses the engineering development workstation, the viewer runtime and the engineer’s color printer. Modifications to the graphics and all development will take place on the engineering development workstation. Workstations will have a base load of MS Office Standard 2007 Edition, Adobe Reader and VOLO Drawing Viewer (or equivalent). Two operator workstations will be provided for the engineering room consisting of a modular desk, chair and document storage.
The tech shelter will have one workstation and a black-and-white printer. This workstation will have a base load of MS Office Standard 2007 Edition, Adobe Reader and VOLO Drawing Viewer (or equivalent). One operator workstation will be provided for the tech shelter consisting of a modular desk, chair and document storage.
The 24 substation workstations will have CIMPLICITY Viewer Runtime, as well as MS Office Standard 2007 Edition, GE Enervista, Adobe Reader and VOLO Drawing Viewer (or equivalent).
Anticipated completion date is Q4-2009.
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- Gycol Recovery System for a Plastics Company
MAVERICK implemented RSView and PLC5-80 with Ethernet and DH+.
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- X-RAY Film Pilot Retrofit for a Chemical Company
MAVERICK helped a chemical company convert from PDP-11/44 to RSView and ControlLogix PLC, using ControlNet.
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- DeltaV Batch Configuration
MAVERICK Technologies performed a DeltaV batch configuration for a major chemical company. The control system for the new processing unit
consisted of 800 I/O points and was configured using DeltaV batch software, QUADLOG Safety Matrix software and an existing Wonderware InSQL Historian
installation.
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- Construction of New Process Unit for Introduction of New Technologies
A major chemical company introducing new technologies to the business group constructed a new process unit consisting of 800 I/O points utilizing a DeltaV
control system with batch software, a QUADLOG safety system with Matrix software and a Wonderware InSQL Historian installation. MAVERICK’s responsibilities
included system maintenance, field equipment system commissioning, initial batch assumption changes and optimizing the batch for cycle times. Due to the new
technologies being called up from the laboratory bench test, many batch and database configuration changes were made during startup, including the creation of new
phases, new areas with multiple operating units and new recipes.
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- Additive and Chip Handling System Implementation
A recent project for a chemical plant included controls for the additives batch make-up systems, two chip conveying systems and motors for three continuous
polymerization lines.
The project required configuration of a Foxboro I/A NT system and Allen-Bradley Data Highways using redundant control processors (CP-40s), redundant
Allen-Bradley gateway processors (IG-30s), AW70 consoles, WP70 consoles, fault-tolerant PLC 5/40s, backup expansion modules, backup communication modules and KE
modules. Foxboro field buses consisted of redundant fiber optics cabling. The DCS architecture utilized a full NT server system. This system was one of the first
large-scale Foxboro NT systems utilizing a node bus. The project size was over 7400 I/O. The project scope included a full staging effort of the additives and chip
handling systems in the Pensacola office for customer acceptance testing. MAVERICK engineers participated in field precommissioning, startup and field
coordination of vendor areas at the plant site.
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- Compressor Control System Upgrades
MAVERICK performed engineering to replace a pneumatic control system on one air compressor, one ammonia compressor, one synthesis gas compressor and
refrigeration loop controls with a Foxboro I/A - based control system. This project included systems
configuration and design, instrumentation and electrical design, plus advanced simulation using VPLink, installation management, simulation and system startup.
Supervisory and anti-surge controls were included with each compressor control system.
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- Major Chemical Plant.
MAVERICK Technologies provided project engineering and construction services for a turnkey replacement of an 8000 I/O point CRISP DCS system with an Emerson Process Management DeltaV DCS system in a polycarbonate facility. The polycarbonate production facility is broken into 81 separate process areas that begin with feedstock preparation and reaction processes and end with product finishing and utility areas. The project scope included the following responsibilities.
- Overall project management
- Documentation of existing control system software functionality
- Conversion of existing control system functionality to DeltaV configuration
- Provided over 600 P&ID-style process graphics for plant control
- Process simulation of the new control system hardware and software by process module
- Configuration of an OPC interface to an existing IP/21 historian
- Design and fabrication of new DeltaV DCS cabinets
- Design and construction of new control system in parallel with existing CRISP system operation
- Design and installation of a new uninterruptible power supply and power distribution system for the new DCS
- Created a construction package detailing the control system installation and field wiring cutover process
- Design and configuration of an off-line operator training and certification system using a low-fidelity process feedback simulation model
- Performed operator training and certification on the new control system
- Provided all supervision and craft labor for the cutover and commissioning of the new control system during a planned 30-day outage
- Provided commissioning services for the new control system during and directly after the planned 30-day outage
- Provided a complete as-built documentation package at the conclusion of the project that includes new process operating descriptions and instrument loop sheets for the entire plant
- Chemical Felt Washing Skids.
Project consisted of design, programming, and start-up services for Siemens and Triconex PLCs in a Chemical Building that supplied a Semi-Conductor Wafer FAB.
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- Chemical Facility supplying a Semi-conductor Wafer FAB.
Project consisted of Siemens S5 programming for the process skids. Project included approximately 20 I/O per skid.
Siemens Energy & Automation, Tucker, GA
Manufacturing Lines Productivity Application: Project consisted of developing custom Siemens PLC and Visual Basic applications to develop a “productivity solution” for the manufacturing line. Siemens S7 315 2DP PLCs were used for the project.
Food and Beverage Projects
Life Sciences Projects
Manufacturing Projects
Oil and Gas Projects
Publishing Projects
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- Control System Cleanup.
MAVERICK completed a project for a formaldehyde plant where no major work had been performed on its Siemens Moore APACS platform in three years. Due to changes in I/Os over time, numerous alarms and tags were no longer correct or appropriate. MAVERICK was asked to clean up and refit nonexistent points, as well as to review and modify the DCS and HMI functionality with the client. This work was completed swiftly, utilizing MAVERICK’s quality standards for verification and testing.
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