DCS Migration: Dow MOD-V to ABB 800xA - CGK Consulting Group, Inc

Project Overview

From 2013 to 2017, CGK Consulting Group played a major role in the Americas Styrenics PAMU / M5R project to replace the proprietary Dow Chemical Company MOD-V process control system with a commercially available option. Americas Styrenics was formed in 2008 when a joint venture between Dow Chemical and Chevron Phillips Chemicals was formed as a strategic alliance in North and South America in the sytrene and styrene polymers business. In 2010, Dow Chemical would divest its ownership of Americas Styrenics to private equity, leaving the company operating five heritage Dow sites, running nine reactor trains, and processing over 13,000 I/O on MOD-V process control systems.

CGK was positioned as an excellent system integrator selection for Americas Sytrenics, having experienced process, safety, and automation engineers that previously practiced under the Dow manufacturing discipline philosophy. This natural fit allowed CGK to immediately recognize the challenges of replacing the highly capable MOD-V system and meeting or exceeding the process control excellence Americas Styrenics was accustomed to. In 2013, CGK began to assist the Americas Styrenics Process Automation Group in the Dow MOD-V migration process

Project Stats

Joliet

2,200I/O

2014

Hanging Rock

3,100I/O

2015

Cartagena

2,800I/O

2015

Allyn's Point

3,200I/O

2016

Torrance

2,900I/O

2017

TOTAL

13,000I/O

2014-2017

Consulting, Engineering, & Technical Services

Over the course of the project, CGK Consulting Group’s consultants, engineers, and technical resources helped Americas Styrenics work through all phases of the Dow MOD-V to ABB System 800xA process. These efforts include, but are not limited to:

Forward Engineering:

DCS System Selection
Process Control System Functional Design Specification
Custom Extension of ABB 800xA Libraries for improved functionality
Custom CGK Libraries for improved functionality
Forward Engineering Tools & Work Process Automation
Control system power analysis and migration strategy

Plant Documentation Audit & Aggregation:

Prework Phase: Plant documentation verification and DCS migration preparation
- Creating and verifying “Smart” P&IDs using the CGK P&ID Tool for MOD-V migration
- Creating and verifying “Smart” MOD-V graphics using the CGK MOD-V Graphics Tool
- Documenting control room junction box terminations using the CGK CRJB Tool
- Generating preliminary “as-built” I/O lists using the CGK AutoDoc Analysis Tool
- Identifying mandatory and optional I/O migration projects to include in the migration process
- Cross validating plant documentation using CGK’s document comparison tools
- Defining the future state I/O list and channel configuration parameters
- Defining application / unit boundaries for 800xA control code using MOD-V Graphics Tool

Layout, Hardware, Cabinet, and Migration Cable :

Controller & I/O Panel Design
Mass Termination Harness Design
Hardware Acceptance Testing
Control Room Layout Design
Network & Power System Infrastructure Arrangements
Construction Management Services

Software & Systems Engineering :

Server Configuration
Custom ABB 800xA Hardware & Base Library Extension Development
Custom CGK Process Control, Graphic, and Workplace Library Development
Process Control Code DowTran Reverse Engineering
Process Control Strategy Documents (PCSD)
BCPS Process Control ABB 800xA Control Module Code Re-Engineering
SIS Code Implementation
Process Control Simulation Development & Implementation
HMI Graphic & Simulation Graphic Development
Task-Oriented Graphic Displays
Software Configuration Testing
- Unit / Application Level Testing
- Integrated / Inter-application Level Testing
- SIS & Shadow Element Integrated Testing
ABB Workplace & Functional Structure Configuration
Automated Reporting Tools
Plant Performance / KPI Dashboards
Alarm Analysis & Rationalization