Questar - Blacks Fork Processing Plant

RCC’s mission was to replace the Allen Bradley-based PLC 5 controls system in fractionation train l and Blacks Fork I cryo and associated support equipment and Emergency Shutdown system (ESD) with a new Allen Bradley-based Control Logics PAC and iFix HMI software.

Located in Southwest Wyoming, the Blacks Fork Processing Complex is composed of three NGL extraction plants with a total of 785 MMcfpd of gas processing capacity: Blacks Fork I cryo—85 MMcfpd, Blacks Fork II cryo—420 MMcfpd, and Blacks Fork JT—280 MMcfpd, and two fractionation trains: train one at a capacity of 5,000 Bbl/d and train 2 at a capacity of 10,000 Bbl/d.

 

To accomplish this mission, RCC needed to create a new Cause and Effect Matrix and Controls Narrative to create the necessary programming. Since this processing plant was in operation, the greatest challenge was minimizing any downtime, scheduled or not. Our team successfully created and executed a plan and design to meet this requirement, which saved our client from costly shutdowns.

 

 

Physical space for new equipment was also a significant challenge on this project. The RCC automation and engineering teams definitely did some head scratching on this one. An RCC design and coordinated plan were created, and several meetings, discussions and presentations were held to obtain client approvals. The plan included a 48-hour scheduled plant-wide shutdown wherein several maintenance projects were completed throughout the site. Commissioning of the new PLC and HMI system would be completed after the shutdown over a two-week period.

RCC participated in and, in some cases, led the hazard and operability study (HAZOP) and the Process Safety Management (PSM) program Management of Change (MOC) generation. RCC and Questar’s operational leadership team worked side by side to create the HMI screens, Cause and Effect, and Controls Narrative.

For the commissioning of this new controls system, RCC generated work packages, including procedures, drawings and check sheets for all terminations, control power distribution, field instruments and equipment for use by the commissioning team. These work packages provided critical progress tracking, as project updates were required every hour of the shutdown. The Cause and Effect were verified line by line and signed off by both RCC and the client representatives. RCC's work packages provide unparalleled efficiency throughout commissioning processes and are often used post-project for maintenance.  This project was completed safely and successfully, within the required time frames and budget.