Overview
When the world’s largest independent petroleum refiner needed to update its gas and fire detection control system, its engineers had several demands for the company entrusted with the task. The first was that they wanted to deal with people who understood, not only the requirements of the job, but also the general engineering ethos that runs their business.
“Birds of a Feather Flock Together”. Engineers like to work with other engineers. Valero chose IES.
The Task
The specification was for a gas and fire detection control system for three 27,000 square metre butane tanks and a vapour recovery station. Valero required a Triconex-TriGP-based Programmable Logic Control system. It needed to interface with field mounted Honeywell flame detectors, gas detectors, and line of sight detectors, as well as transmitting the data to the site-wide distributed control systems. In addition, it was to trigger local alarms.
The Challenge
To design and manufacture the Programmable Logic Control Panel, to develop the software for the Rockwell panel-mounted human-machine interface, and to test and commission the system.
The Strategy
IES worked on the development of the system with a view to minimising, or avoiding, down-time. Where possible, existing systems were to be updated rather than replaced, and Valero’s own engineering team were to be kept informed of developments at all stages of the project.
The Design and Implementation Teams
Software and hardware engineers of the highest calibre are required for any project involving safety where explosive gas is concerned. Valero selected IES to update its safety and alarm systems.
The Outcome
Each stage of the system was tested individually, and then in sequence, and it worked to the entire satisfaction of the client’s engineers. The field mounted gas and fire detectors signalled the alarms to the control room’s critical alarm mimic, whilst simultaneously providing individual gas and flame detector status to the Distributed Control System over the Modbus serial communications protocol.
The system successfully activated all the beacons and sirens in the general vicinity of the tanks and the vapour recovery station.
The new fire and gas detection system developed and implemented by IES, which replaced the existing system, has provided a wider and more robust coverage.
Did You Know?
As well as being the world’s largest independent petroleum refiner, Valero is a leading marketer, ethanol producer and corporate citizen.
There’s a shamrock connection – Valero issues its own private label credit cards for its stations through its credit card-only subsidiary, DSRM National Bank. The initials stand for “Diamond Shamrock Refining & Marketing”.
IES used a Triconex-TriGP-based Programmable Logic Control system based on its patented Triple modular redundancy (TMR) industrial safety-shutdown technology. Triconex is the largest TMR supplier in the world.