Case Study
Fermentation Tank Farm DeltaV Mechanical & Controls Upgrades
Challenge:
A leading global pharmaceutical/biotech company and a Fortune 100 top employer needed to evaluate several tank farms with regards to their process design as well as convert their process controls from one system to another. The tank farms had undergone field work over time that had not been documented and the client needed to better understand the existing conditions.
Solution:
Valdes worked with the client to review piping and instrumentation diagrams (P&IDs) for each system and performed walkdowns to validate their accuracy and summarize the instrumentation and control valves. Valdes also reviewed the operational philosophy/design change recommendations with client stakeholders. This included overfill protections, hi/low level interlocks, spill detection, environmental/LEL remediation and human error risk remediation to prevent cross-contamination and incorrect system line-up. There were obsolete instruments found within the tank farms and Valdes identified them and made recommendations for their replacements. An evaluation of existing manual valves was necessary, as well, and Valdes recommended and detailed the implementation of automation of manual valves in accordance with the process evaluation.
Impact:
Valdes performed the front-end engineering and design to evaluate and design integrated tank farm vessel instrumentation, monitoring, and automated protections to provide safe uninterrupted service. Valdes also coordinated with the vendor to define and execute the Provox to DeltaV conversion to update the process controls.
SERVICES:
Mechanical
- Facility Design & Plant Layout
- Equipment Selection
- Material Handling & Dust Control Systems
- Rotating Equipment Sizing & Specification
- HVAC
- Fire Protection & Detection
- Plumbing
- Fluid Heat Tracing
- Blending & Mixing Systems
- Heat Exchanger Selection
- Plant Utilities
- Industrial/Hygiene Ventilation
- Equipment & Piping Specifications
- Field Walkdowns/Constructability Review
- Pressure Vessel Design
Process
- Simulation & Modeling
- Studies
- Technology Evaluation & Selection
- Front-End Project Development
- Process Optimization
- PFD/P&ID Development
- Heat & Mass Balance
- Equipment Selection & Specification
- Process Equipment Evaluations
- Relief Device & System Analysis
- Utility System Design & Evaluation
- Process Control Design
- Process Scope Development
- Effluent Handling System Design
Instrumentation & Controls
- PID Controller Application & Specification
- Instrument Selection & Specification
- Instrument Index & I/O Lists
- Control Valve Sizing & Specification
- Instrument Loop & Interconnection Diagrams
- Smart Plant Instrumentation/INtools
- HAZOP Participation
- Control Panel Design Instrument Location Plans
- Installation Details
- Instrument Commissioning
- Safety Instrumented Systems (SIS) Implementation*
- Engineering & Design in Accordance with ISA84 & IEC-61511 Standards
- HMI, MMI, & SCADA Functional Specifications
- Operator Interface Specifications
- Operator Usability Studies
- PLC & DCS
- Specification Selection
- Functional Descriptions
- Ladder Logic
- Hardware Interface
- System Architecture Drawings
- HART & Foundation Fieldbus
- Control Room Layout & Design
- Control System Training Manual
- Site/Factory Acceptance Testing
Piping & Plant Layout
- Piping Layouts
- General Arrangement Drawings
- Line Studies
- Piping Isometrics
- Equipment Arrangements
- Vessel Nozzle Orientation
- Vessel Platform & Ladder Layout
- Underground Piping Layout
- Process & Utility Piping Design
- Construction Field Support
- High Definition Laser Scanning & 3D Modeling/Design
Plant Services & Support
- Maintenance Engineering
- TAR Engineering
- Inspection Services
- Aerial (drone) Inspection and Scanning
- Process Troubleshooting
- Infrastructure Program Management
- Engineering and Technical Studies/Analysis
- Multi-discipline Technical Support and Staff Augmentation
- Document Management