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Fuel Terminal and Pipeline Remediation System
PLC and SCADA Upgrade
Granger, Indiana

Control System Automation Upgrade for Petroleum Terminal Client: BP

Hull partnered with BP to upgrade the outdated control system for the ground water remediation system at this facility. Since beginning operations in 1953, the terminal has suffered several spillages that resulted in the contamination of an area greater than the terminal site, requiring ground water collection and treatment over a wide geographic area. The on-site system installed consisted of isolated pumps and controls that required manual operation and travel to each location. The system also required flow monitoring which was recorded manually. The off-site system consisted of a rack-mounted computer to control well pumps, air stripper blowers and carbon filters, and monitor flow meters. The Environmental Regulatory Agency required the system to treat a minimum amount of groundwater and be operational 24/7. These requirements and the reliability of the system forced a full-time employee to operate and monitor the facility.

Hull upgraded the control system to reduce downtime, improve flexibility, and allow reduced on site monitoring of the system. Using graphical interface software and data collection capabilities allow the system to be monitored and controlled from remote offices as well as provide automated reporting for the regulating agencies.

The original system was very difficult to troubleshoot and the components had become obsolete. Therefore, a new system needed to be developed to allow operators, maintenance and management to access appropriate information, control, diagnostics, and critical process values. This all needed to be upgraded with minimal down time.

An Allen-Bradley FlexLogix Programmable Logic Controller (PLC) was used as the primary control and was located with the HMI in the maintenance building. The existing rack mounted controls where removed from the control panel and replaced with FlexLogix I/O modules utilizing a ControlNet adapter to communicate to the PLC.

Since the site covered a large area, a communication method had to be designed in order to control and monitor equipment in all areas. An economical method of controlling and monitoring off-site recovery wells had to be developed. A wireless I/O control network was provided and installed, utilizing Elpro equipment. Each well had a wireless panel installed which transmitted data back and forth between a gateway unit located in the PLC panel. The gateway unit communicated to the PLC via Ethernet IP.

Remote access of the system for Supervisory Control and Data Acquisition (SCADA) monitoring and control as well as maintenance/programming support was accomplished by installing a DSL Internet connection.

Other services provided at this facility:

• Hull specified new flow meters and installation details to minimize on-site time required to record totalized flows.
• Hull provided arc-flash NFPA 70E services for the facility while performing the controls upgrade. Hull also helped analyze power issues during the project caused by utility power dropping phases. Hull installed phase monitors throughout the system to shut off pumps when poor utility power is sensed, thus reducing pump failures. Hull's network abilities allowed VPN access to the system from offices of the managing engineering firm.
  

To find out how Hull can help, please contact Hull's Electrical Engineering Division Leader, Andrew Holtom, PE at (614) 793-8777.