INEOS Chlor Significantly Reduces Critical Safety Testing Time on Chlorine Compressor using AMS Suite

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CHEMICAL
INEOS Chlor Significantly Reduces
Critical Safety Testing Time on Chlorine
Compressor using AMS® Suite
RESULTS
•Commissioning time reduced by 50 per cent enabling one
week of additional production
APPLICATION
Trip system on a large chlorine compressor.
CUSTOMER
INEOS Chlor is one of the largest Chlor-Alkali producer in Europe
and a global leader in chlorine derivatives. The Runcorn site, in the
UK, is Ineos Chlor’s largest site.
CHALLENGE
Prior to plant start-up, the 40 inputs to the shutdown system on each
chlorine compressor need to be calibrated and tested. Each
instrument on the compressor and the chlorine systems around it
(pressure, temperature, vibration etc) require calibration and then
driving to the trip point to test the operation of the shutdown system.
The majority of the transmitters are on toxic gas duty and would
normally be required to remain in a completely clean and
decontaminated state until the work was complete. Registered
chlorine fitters would then re-joint the system in a highly controlled
manner before pressure testing it for leaks. Getting this resource to
shadow the instrument team whilst the shutdown tests were
completed was very inefficient and time consuming.
Traditional testing methods would normally mean that the majority
of the mechanical overhaul work would be completed first to give the
assurance that the instrument systems had not been affected by that
work. With so many inputs to the system, the test duration was
significant and prevented other work (such as the pressure testing of
the system with chlorine) from continuing until it was certain that the
instrument tests were complete.
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“By using AMS Suite to drive
the transmitter output we
were able to test the trip
system in parallel with other
work that was going on. This
shaved time off the overall
schedule.”
Paul Young
Automation Manager
CHEMICAL
INEOS Chlor wanted to explore alternative methods of trip testing to
remove the instrumentation tasks from the critical path of the project.
SOLUTION
By using the power of the PlantWeb® digital plant architecture,
consisting of field instrumentation communicating digitally via
HART® communications protocol to AMS® Suite: Intelligent Device
Manager, it was possible to make use of the instruments simulation
mode functionality. This enabled the instrument output, being
read by the analogue trip system, to be varied remotely.
The instruments were decontaminated and calibrated during the
mechanical outage. A team of dedicated instrument technicians
and chlorine fitters were then able to reconnect, working
methodically from one system to the next, rather than having to
connect up piecemeal, as each instrument was tested. Pressure
testing could then take place as soon as the fitters had finished.
Because the instruments had been checked and calibrated the
technicians were highly confident they would function as required
when the plant was operational. All that was then necessary was to
test that the trip system would react correctly once the transmitter
inputs reached set point.
The physical testing of the shutdown system was carried out by
using AMS Suite to drive the output signal of each transmitter to
the tripped state. This work could be carried out at any time once
the mechanical tasks were completed and therefore did not
hamper the ongoing process re-commissioning.
The overall effect simplified the
shutdown planning and resource
requirements significantly and
reduced the overall time to
commission from two weeks to
just one week.
By using the capabilities of the PlantWeb architecture the overall
time that the system was decontaminated was reduced by a
number of days. The overall effect simplified the shutdown
planning and resource requirements significantly and reduced the
overall time to commission from two weeks to just one week.
Emerson Process Management
Asset Optimization Division
12001 Technology Drive
Eden Prairie, MN 55344 USA
Tel: 1(952)828-3206
Fax: 1(952)828-3006
www.assetweb.com
AMS Suite: Intelligent Device
Manager powers PlantWeb
through predictive and proactive
maintenance of intelligent
field devices to improve
availability and performance.
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