Multiple Product Areas Join Forces on Pipeline Project

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Project

New Pipeline and Injection Facilities

Location

Texas

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Background

A new midstream energy company called on EN Engineering for a wide array of services supporting a new pipeline system and injection facilities.

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Challenges

As a new company, the client had not yet developed comprehensive project procedures, so one challenge involved working together to establish new processes and standards. In addition, the project had an aggressive timeline and required the team to work at an accelerated pace.

Solutions

EN Engineering provided project management, engineering, and design services for a new pipeline system consisting of more than 70 miles of 8” and 12” diameter pipeline, as well as five new injection facilities for multiple third-party producers.

Experts from EN Engineering’s entire service portfolio came together to successfully complete the project. The pipeline design team provided oversite of the pipeline routing as well as development of engineering design details, while a facility team provided full mechanical, electrical, civil, and structural design packages, along with hydraulic and surge analysis.

Environmental experts oversaw an environmental survey and provided recommendations for both compliance measures and installation best practices along the pipeline. Several scenarios for flow modeling were evaluated by the integrity team, who also provided recommendations for emergency flow restricting device (EFRD) valves. GIS services were utilized to evaluate alternate pipeline routes and make a commercial recommendation. Designs for cathodic protection were provided by the corrosion team. Finally, procurement experts provided comprehensive support on all equipment, material, and labor contracts, from specification development to expediting and tracking deliveries.

EN Engineering also provided several specialty services, including in-house HAZOP facilitation and shop inspection services, and managed geotechnical, environmental survey, and mill inspection subcontractors. The automation team developed the control philosophy for the injection facilities and interfaced with third-party programmers and PLC integrators.

The EN Engineering team was instrumental in guiding industry best practices and helping the client develop new procedures and standardizations. In addition, they facilitated communications despite several changes in client stakeholders at critical stages during front-end loading and worked at an accelerated pace to meet project deadlines.

“Experts from EN Engineering’s entire service portfolio came together to successfully complete the project.”

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Commissioning Completed On Time Despite Construction Delays

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Project

Commissioning Completed On Time
Despite Construction Delays

Location

Midwestern U.S.

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Background

The client, a multinational energy transportation company focusing on transportation, distribution and generation of energy in North America, required commissioning services and automation for a greenfield 36-inch pipeline.

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Challenges

Commissioning of a large pipeline requires the coordination of all parties involved with design, construction, management, vendors, and operations, and lack of communication can impact the schedule and cost. In addition, with simultaneous construction and commissioning activities happening across multiple facilities, logistics were also a challenge. Finally, construction ran behind schedule at many of the facilities, but the client needed to keep their in-service date due to contractual obligations.

Solutions

Automation services were provided for three compressor stations, and commissioning services were provided for three compressor stations, six meter stations, and 17 remote-controlled main line block valves. EN Engineering wrote the software for the PLCs and the HMIs for the compressor stations, and also coordinated with vendors, operations, construction, construction management, and project management to schedule resources for the commissioning efforts. On-site coordinators and technicians verified operation of all control devices and proper calibration including transmitters, pressure regulation devices, protective systems, valves, and the control system.

To help facilitate communication between all parties, the commissioning project manager hosted a weekly project-wide call with almost 100 invitees. In addition, to manage the simultaneous construction and commissioning activities across multiple facilities, EN Engineering allocated two commissioning leads, one for the compressor stations and one for the remaining facilities, as well as five commissioning coordinators, one per compressor station and two who split responsibilities on the meter and regulation stations and main line valves. This organizational structure allowed for operations and construction to have points of contact at each facility while still allowing efficient communication for global issues.

To help the client meet their in-service date and contractual obligations, the EN Engineering team mitigated the impact of the construction delays by working closely with the contractor to prioritize work and commission in parallel with construction activities. The EN Engineering team facilitated the hand off between construction and operations to bring the pipeline and facilities into service on time, and the client expressed great appreciation for the team’s capabilities.

“EN Engineering facilitated the hand off between construction and operations to bring the pipeline and facilities into service on time.”

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EN Engineering Commissions Complex, Interstate Pipeline Project

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Project

Transmission Pipeline Automation and Commissioning

Location

Southeastern U.S.

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Background

Our client, a large US pipeline operator, contracted us to complete automation and commissioning for their pipeline. The natural gas pipeline transports over 1 billion cubic feet per day across 517 miles. The project included the compressor station automation and commissioning, as well as commissioning for the M&R site and main line valve. The facilities included 496 miles of 36” pipeline, 21 miles of 24” pipeline, three grass roots compressor stations, four meter and regulation stations, thirty-three main line valve sites, controls and automation, and full commissioning services at all facilities.

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Challenges

This large-scale project covered 517 miles across 3 states and required diligent tracking of multiple site construction schedules, staffing, and staging logistics. In addition, the project had an accelerated in-service date, and the team was tasked with construction prioritization while still working in tandem with the construction management.

Solutions

In order to meet the demanding schedule and project complexity, EN Engineering assigned a project director to manage the entire project and then split the project into three manageable pieces: 1) compressor stations, 2) M&R sites/main line valves, and 3) rovers to assist on demand at other sites. These smaller, nimble teams enabled us to react quickly to client demands and changes in the project scope.

The project teams performed all compressor station programming, pre-commissioning, and commissioning for three compressor stations, 33 mainline block valves, and four meter and regulation stations. The project included creation of site-specific, detailed commissioning manuals with start-up procedures describing the sequence of events for commissioning each of these systems, including visual inspection and energization support; PLC/HMI software development; factory acceptance testing; site acceptance testing; tuning; and training. In addition, EN Engineering provided standard operator maintenance and on-site training demonstrations for all written applications, including HMI display operation; loop and point configuration; custom applications; and reports.

The EN Engineering team met the demanding requirements and accelerated in-service date for the complex, interstate pipeline expansion. The project spanned eight months and employed as many as 30 employees who worked in excess of 22,000 hours. Resources were tightly managed to minimize cost and maximize effectiveness. Efficient and effective communication and daily project meetings ensured a successful, coordinated effort.

“The EN Engineering team met the demanding requirements and accelerated in-service date for the complex, interstate pipeline expansion project.”

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CRM SCADA Updated to Unified, Modern Architecture

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Project

CRM SCADA Upgrade
Location

United States

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Background

A leader in the gathering, transportation, processing, and storage of natural gas was operating a number of gas compression pipelines using a mixture of legacy Human Machine Interface (HMI) implementations that were not unified. They approached EN Engineering seeking a solution that would encompass conversion of HMI assets across their facilities to a common platform that would leverage centralized code management and template-driven design to comply with federal mandates in 49CFR192 for Control Room Management.

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Challenges

With more than 100 stations geographically distributed from Texas to Maine, the size and scope of the completed system presented implementation challenges.

Solutions

EN Engineering created processes and tools to facilitate consistent and accurate HMI conversions to a common, modern architecture. Using these processes and tools, EN Engineering worked directly with the client to complete the conversion of more than 100 stations into a single, centrally managed HMI infrastructure. The customized tools assisted in the batch conversion process, enabling accurate progress reporting and programmatic conversion where applicable. Project-specific automated reports were generated and reviewed by the project team weekly.

An unprecedented HMI architecture, implemented under Wonderware System Platform, was created to leverage template- driven design and reduce the amount of site-specific duplication. Computer Workstation Configuration was also script-driven, reducing the possibility of human error and increasing consistency in the finished systems. Communications between all system computers were optimized through customized code to support the large deployment under Wonderware System Platform. Managing the completion of the individual station HMI conversions was facilitated using Kanban methodology and daily stand-up meetings amongst the project team to ensure smooth execution and address execution blocks early and effectively.

“EN Engineering created processes to facilitate accurate HMI conversions to a modern architecture, and converted more than 100 stations into a single, centrally-managed HMI infrastructure.”

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Compressor Station Control Panels Designed, Programmed, and Commissioned with Limited Timeline

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Project

Gibson Compressor Station

Location

Pennsylvania

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Background

The client, a large energy company with assets across the United States, tasked EN Engineering with designing and fabricating their Gibson Compressor station control panels, programming the station’s logic controllers and operator interface, and assisting with the installation and commissioning at the facility. The Gibson Compressor station was designed and constructed in 2013-2014 and is part of a gathering system in Eastern Pennsylvania that conditions and compresses natural gas from local wellheads so it can be delivered to interstate pipelines.

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Challenges

With a limited timeline to complete the design, EN Engineering had to diligently maintain a demanding project schedule to ensure timely project delivery.

Solutions

The EN Engineering team completed a detailed design package for the station control panels, procured all equipment for the control panels, and oversaw the panel fabrication process. In addition, EN Engineering completed the programming for the two programmable logic controllers responsible for maintaining the safe operation of the station and programmed the operator interface system to allow the station operator to monitor and control the facility from the control room. The team also provided on-site commissioning support to verify the functionality of all station instrumentation and control systems and assisted with the startup of the station and compressor units.

“With a limited timeline to complete the design, EN Engineering had to diligently maintain a demanding project schedule to ensure timely project delivery.”

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Creating a Variable Load BESS Control System

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Project

Hybrid Power Generation System

Location

California

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Background

A leading supplier of electricity in California had an existing LM6000 gas turbine built to operate at peak power of 50 megawatts. Their goal was to integrate a 10 megawatt Battery Energy Storage System (BESS) and allow the turbine to operate from 2 megawatts to 50 megawatts.

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Challenges

The existing turbine, emissions system, and compressor system were designed to run at full load, so changes in communications and sequencing were required for the equipment to run at variable load. The system had to be integrated into the state power grid while still maintaining current and legacy control. Due to its location, the facility required extremely stringent emissions standards while testing and operating the new system.

Solutions

The design-build project involved the integration of a revolutionary power generation system into the current company power infrastructure, and then into the national grid system at two different locations. The revolutionary Hybrid Power Generation System maximizes the client’s existing capital assets by enhancing them with modern technology. The expertise of EN Engineering’s Automation team allowed the project to progress smoothly, remain on schedule, and produce a flexible and responsive system.

With the addition of the BESS to the turbine, it moved the system into a different power assist model. The EN Engineering team worked with the turbine and BESS manufacturers to create a groundbreaking control system that would handle the communications and sequencing changes required for this new system. The control algorithms that were specially developed for the hybrid system will translate to other applications in the power generation industry.

A major benefit of the new hybrid system is a substantial energy savings that is achieved from the BESS syncing with the grid and adding or shedding power as needed without starting the turbine. The turbine only needs to start if the demand exceeds the storage of the batteries.

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Natural Gas Compression Station System Conversion

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Project

Allen-Bradley PLC5 to ControlLogix Conversion

Location

Utah

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Background

The client had an existing control system that utilized discontinued Allen-Bradley PLC5 Series controllers. The system conversion project included replacement of the outdated control system hardware and software, as well as the design and installation of a fiber network to replace the existing ControlNet communications with EtherNet/IP.

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Challenges

The downtime allowed to execute the conversion was limited, and any schedule delays would result in substantial costs to the client.

Solutions

EN Engineering was responsible for all aspects of the project. The fiber network design included all necessary cabling, patching, and media conversion systems to accommodate new and existing control hardware at the station. The existing PLC5 programs were converted to the ControlLogix platform, and were modified to take advantage of modern programming standards available in the ControlLogix system. A complete proof-of-concept test was performed to validate the design prior to installation.

EN Engineering contracted and managed the installation of the new communication and control system equipment at the station. Due to the limited outage time, some of the installation was completed prior to the actual station outage. EN Engineering verified the new PLC systems and fiber network before the official station shutdown.

During the outage, a full commissioning of all field instrumentation was required to validate the new hardware and software systems, and a complete functional test of all control and shutdown systems validated the new programming. EN Engineering’s commissioning team worked 24-hour shifts until the commissioning was complete. In addition, EN Engineering created an outage schedule detailing the required tasks completed during each shift. This schedule was used as the primary metric for tracking progress during the installation and commissioning.[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]

Rail Rack Automation Upgrade Enhances Capabilities

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Project

HUG Rail Rack Expansion

Location

Kansas

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Background

Our client needed to expand a rail rack with six compressors for loading and unloading a new 26 railcar rack. In addition, they required a new valve manifold and four additional control valves.

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Challenges

EN Engineering’s automation team was tasked with creating a new single AB PLC program that would incorporate six new compressors with individual AB PLCs. The single PLC program included logic for four shutdown valves, four control valves, two fin fans, an ESD circuit with multiple push buttons, multiple transmitters for monitoring pressure and temperature, additional I/O points, and communication logic for communicating to the six compressor skid PLCs.

Solutions

The EN Engineering team developed the PLC panel design and oversaw building and evaluation. A new redundant mercaptan system was installed and added to an existing PLC, along with a pump for injecting methanol. All the information was brought back into the existing control room InTouch HMI program, where it could be monitored and controlled by the operator. The team created a new PLC program, modified an existing PLC program and an HMI application, developed communication to the mercaptan system, and created PLC panel drawings and loop folders for checkout. The client is now able to bring in a 90-car unit train and unload residual vapors from the railcars if they are already empty, or unload the product if they are full.

EN Engineering’s automation team was tasked with creating a new single AB PLC program that would incorporate six new compressors with individual AB PLCs.

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Challenging Pipeline Upgrade

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Project

Pipeline Automation Upgrade

Location

Midwest

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Background

One of the country’s largest midstream companies required an infrastructure upgrade to an existing pipeline to optimize the quality of outbound products. The project took five years to complete from original conception to field implementation.

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Challenges

Because the facility has one of the highest line throughputs in the country, the system design had to meet extremely high pipeline throughput demands. In addition, the project presented a number of networking challenges, as multiple customer communication networks required conversions. Finally, because the client’s pipeline transports a vast array of products, each had to be considered individually with regard to control system response.

Solutions

EN Engineering utilized an advanced algorithm to determine outbound product properties, which significantly reduced the amount of time to initialize the control system. To address the wide range of pipeline product flowrates, a multi-injector control solution provided full turndown on fungible product flow ranges. Finally, the team installed a fully redundant control network and automatic failover systems for critical project-related devices including servers, applications, databases, pumps, drives, and analyzers. Platforms utilized included Wonderware System Platform, Rockwell Automation software, and Allen-Bradley ControlLogix hardware.

The system design had to meet extremely high pipeline throughput demands and presented a number of networking challenges.

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Complex Export Terminal Control System Installation Made Easy

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Project

Export Terminal Control System Installation

Location

Houston, Texas

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Background

One of the largest energy infrastructure companies in North America needed to build a new terminal on the Houston Shipping Channel to export gasoline, naptha, and diesel fuel directly into large maritime vessels.

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Challenges

The terminal was a brand new facility, integrating 12 large tanks (1.5M barrel capacity), 16 pumps, 200 motor operated valves, 150 measurement instruments, and 4 vapor recovery systems. The facility also had barge and ship docks to facilitate vesselloading operations on the shipping channel. The export terminal was to be completely automated and controlled from the control room across the channel. This meant that all indicators, controls, and alarms would need to be accessible remotely. Because the existing control system was built on technology from previous decades, the new export terminal control system needed to remain compatible with both old and new technologies.

Solutions

A project execution plan and project schedule were created prior to the control system design. The EN Engineering team was embedded with client resources to operate in a unified manner. PLC, network, and computer hardware were chosen that precisely followed the client’s standards and compatibility with past/future systems.

Rigorous testing was performed with strict adherence to ISO standards, and frequent checkout documentation audits were completed.

At installation, the benefits of the testing efforts were realized. Only 50 percent of the expected travel to the job site was required, as the client was able to install much of the system without assistance. In addition, the final list of desired modifications after installation was minimal. The project was completed on schedule and under budget. More importantly, the client was happy and placed EN Engineering on bid lists for other projects in Texas and Louisiana.

The EN Engineering team was embedded with client resources to operate in a unified manner.

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