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Project Gallery | Chemical and Petrochemical Projects
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 client's needs.
Completed Projects
- Major Chemical Manufacturer Improves Ethylene Oxide (EO) Selectivity and Extends Catalyst Life by Implementation of DCSResident Advanced Process Controls (APC’s) and Operator Advisory Tools
EO reactor operation presented the most bothersome control problem in this unit. Because improper reactor operation can lead to conditions in which the reactant concentrations violate explosion limits, the operators tended to run the reactor far away from optimum conditions, resulting in poor EO selectivity and excessive catalyst degradation.
EO operations personnel sought an improved control scheme that would ensure safe reactor operation while maximizing selectivity and extending catalyst life under widely varying process conditions. This manufacturer sought the help of MAVERICK Advanced Automation Solutions personnel to analyze the control problem and design and implement an effective solution.
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- Manufacturer of Specialty Engineering Plastics Improves Process Yields Through Advanced Process Control (APC)
A major plastics manufacturer was producing multiple grades of plastic on the same production lines and needed a more efficient method of transitioning from one grade to another. The company’s existing manual transition process was slow and inconsistent, and resulted in wastage and downgrading of valuable product.
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- Major Plastics Manufacturer Increases Production and Reduces Operator Workload Through Advanced Process Control (APC)
A European manufacturer of high-value engineering plastics needed to boost its production rate to meet increased demand for Bisphenol A (BPA), a key intermediate, and the final product, a highvalue polycarbonate resin. Although there were no immediate plans to install new equipment, and all other debottlenecking steps had already been performed, the manufacturer had to find a way to maximize its production of BPA.
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- MAVERICK Technologies Performs APC Opportunity Survey at Plastics Manufacturing Plant
MAVERICK Technologies announced today that it is currently completing a study to review each of the processes at a large plastics manufacturer, with the intent of developing design requirements to improve the productivity through advanced process control (APC). APC provides more stable plant operation, tighter control of variables related to quality, operation closer to constraints and more diligence than the best operator. Results include greater throughput, better yields, higher quality and improved productivity.
- MAVERICK Technologies Wins Automated Flow Valve Control System Project
MAVERICK Technologies announced today that it recently created an automated flow valve control system for 19 chemical solution tanks at a large film processing company. The Allen-Bradley ControlLogix PLC platform and RSView HMI were selected for this project. MAVERICK developed the initial scope of work, which was then used as the driving project documentation. Working in partnership with the client, MAVERICK specified the field instrumentation for the project and developed the tag list database, including I/O addresses, naming conventions, RSLogix 5000 programming and batch recipe programming. MAVERICK also created RSView HMI screens based on a standard developed with the client. Finally, MAVERICK delivered electrical schematics, system architecture layout drawings and instrument location drawings for the project.
- Sulfuric Acid Plant
MAVERICK Technologies provided complete scope development, equipment specification, configuration services, installation engineering, construction services, and startup support for a control system replacement in a world class Sulfuric Acid and SO2 Generation facility in Houston, Texas. The project required the complete replacement of an existing control system utilizing a Toshiba DCS and a Gould Modicon 584 Burner Management System on the sulfur decomposition furnace. The new control system consisted of an Emerson DeltaV Process Control System utilizing five M5 processors and a Siemens / Moore QUADLOG Burner Management System. Total I/O count consisted of approximately 400 analog inputs, 50 analog outputs, 200 digital inputs, 100 digital outputs, and two serial links with the Siemens / Moore QUADLOG and a Continuous Emissions Monitoring System (CEMS). MAVERICK Technologies provided the expertise and experience to integrate the Process Control System with the Burner Management System using the single operator interface of the DeltaV system.
- Aluminum Heat Treating Furnaces
MAVERICK Technologies provided engineering, configuration and control system cabinet integration services for a DeltaV control system on four electrically heated vertical heat treat furnaces in Spokane, Washington. The control system includes four M2 processors, a ProPlus Station, three operator stations and an application station. MAVERICK configured the batch control sequence for automated metal tracking, sequence timing and heat soaking parameters, and generation of load reports at the conclusion of a heat treat / quench sequence. MAVERICK Technologies programmed an interface in the DeltaV Application Station using OPC software to communicate with the client’s data tracking system for automatic batch sequence downloading and batch performance tracking. Total system I/O included 160 thermocouple inputs, 136 analog inputs, 40 analog outputs, 192 digital inputs and 128 digital outputs.
- Sulfuric Acid Plant
MAVERICK Technologies provided complete scope development, equipment specification, configuration services, installation engineering, construction services and startup support for a control system replacement in a world-class Sulfuric Acid and Spent Acid Recovery Plant in Baytown, Texas. Project involved documenting the existing ABB Bailey INFI 90 process control system (PCS) and burner management system (BMS), including both field hardware and application software, and dividing the plant controls by function for implementation in a DeltaV process control system and a Siemens / Moore QUADLOG Burner Management System. The NFPA 8501 standard was followed closely to define the control system split between the PCS and the BMS. MAVERICK Technologies has provided complete control system configuration services for the DeltaV, the QUADLOG and the interface of the two control systems. The operator interface for both control systems was implemented on the Emerson DeltaV HMI.
- Polyols Batch Reactor
MAVERICK Technologies provided complete scope development, equipment specification, cabinet integration, configuration services, installation engineering, construction services and startup support for a control system replacement in a Polyols batch facility in Houston, Texas. MAVERICK had total system responsibility including development of a set of project P&IDs to define the project scope boundaries prior to project award. The existing control system was a conglomeration of pneumatics and analog electronics, and the project included specification of new field instrumentation to replace the existing pneumatic devices. The new control system included a DeltaV control system that utilized ten pairs of redundant MD controllers and over 1400 I/O points, and a Siemens / Moore QUADLOG safety shutdown system was provided to detect and prevent runaway exothermic reactions. The majority of the conversion from the old control system to the new control system was handled with the plant in full operation. MAVERICK employees assisted the owner in analyzing which systems could be implemented without impacting plant operations, and managed the effort to minimize the systems to be converted during a plant shutdown. In addition to the process control configuration of the DCS, MAVERICK engineers were also responsible for implementing the Batch Executive, Batch Historian and recipe management systems for the various Polyols products produced at this particular chemical plant facility.
- Controller for an Aluminum Dross Press
Project consisted of programming and debugging for a Siemens S5 control system on an Aluminum Dross Press. Control flow charts and ladder logic were used for the code development. Approximate I/O count was 32. Dorlastan (Spandex) for Textile Industry: Project (two year) consisted of Start-up, commissioning, programming and maintenance support for a Siemens PLC and Fisher Provox Control System for the Dorlastan process. Applications included polymerization, extrusion, and winding of the fiber. Three (3) 155U, Six (6) 135U, and forty (40) 90 processors were used on the project. Project responsibilities included finalizing, modifying, troubleshooting the PLC logic, start-up and commissioning. statement lists and ladder logic were used in the code.
- 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
Completion date was 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 turn-key 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.
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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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