Electrical, Instrumentation & Control

The Client
Centrica Storage Limited are a leading Gas Storage Business operating one of the largest gas storage facilities in the UK.

The Challenge
GSA were approached to produce a technical memorandum which investigated and evaluated current electrical generation technologies available to produce standby electrical power for the Centrica Storage Gas terminal at Easington. This included investigating National and International strategies, the analysis of historical data of existing load shedding and Triad practises and procedures, standby generator use, equipment availability and reliability

The Solution
Various options were evaluated taking into account current environmental legislation. This resulted in a recommendation to Centrica Storage Limited based upon life-cycle cost.

Feedback
Ongoing

The Client
Caparo Merchant Bar (CMB) produce hot rolled sections from their Bar Mill at Scunthorpe on a continuous shift basis. The reheat furnace combusts Coke Oven Gas with air to achieve the required rolling temperature controlled by a Eurotherm Process Automation system. The existing control system was obsolete and spares where difficult to obtain putting future reliability and availability into question.

The Challenge
The scope of the project included the production of a user requirement specification that could be used by CMB as part of an enquiry package for the replacement of the existing furnace control system. The package had to take into consideration new compliance legislation with respect to DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) and ATEX. In addition, the requirements of IEC 61508 and IEC 61511 relating to safety integrity levels (SIL) had to be considered and this led to a review of the safety strategies associated with the furnace and control system in the form of a HAZOP (Hazardous Operations Study). SIL levels were identified and incorporated into the design of the control system. The provision of suitable housing for the furnace control equipment was identified within an existing defined location including all minor civil works, building works, heating, ventilation, lighting & fire detection systems.

The Solution
A user requirements specification was produced including input from other disciplines with Electrical‚ Instrumentation and Control documents included: (but not limited to)

• Furnace combustion control system including shutdown systems, alarms, operator interfaces, SCADA, field equipment & certified junction boxes
• All power supplies to the new combustion control equipment
• Cabling, support systems, junction boxes and other hardware
• Site Supervision
• Factory Acceptance Testing (FAT) including witness testing
• Site Acceptance Testing (SAT) & Commissioning
• Personnel Training
• Documentation
• Spares

Typical documentation provided:

• Equipment lists & spares lists
• Design & Construction Drawings
• Instrument schedules
• Valve Schedules
• Cable Schedules
• Interconnections Wiring Diagrams
• Earthing Schedules

The Client
British Energy (BE) proposed to upgrade their oil storage facilities at the Eggborough Power Station in order to fully comply with the requirements of "The Control of Pollution (Oil Storage - England) Regulations 2001".

The Challenge
GSA and RWE completed an initial study for BE which looked at the options available. From this the scope of work included the preparation of multi discipline detailed designs for the modifications.

The Solution
GSA provided a full electrical and instrumentation design for the proposed modifications including design & specification of power & control scheme including system earthing, tanker unloading earth proving, equipment selection, lighting & small power. Instrumentation scope included the tank level alarm & trips, temperature control and emergency shut down systems.

The Solution
The Electrical, Instrumentation & Control documents provided to the client included:

• Power Distribution Specification
• Earthing Specification
• Trace Heating Specification
• Lighting Specification
• Cable Schedule
• Cable Layout
• Line Diagrams
• SIL Determination
• Instrument Specification
• Loop Diagrams
• Control Panel Design
• Materials Take Off
• Tender Package

Feedback
The project was delivered on time and to budget.

The Client
Corus in Scunthorpe is one of the largest iron and steel manufacturing sites in the UK, employing over 4,000 people with a capacity of producing over 4.5 million tonnes of a steel per annum.

The Challenge
GSA were approached by Corus to complete a rolling programme of Safety related studies and evaluations. These projects were located in the following areas:

• Continuous casting plant (Caster 5)
• Medium Section Mill
• Rod Mill
• Bloom and Billet Mill

The Solution
Each project involved the verification of control loops identified as have a verifiable Safety Integrity Level (SIL). Verifications were performed and recommendations were provided to the client during the investigations and final reports.

Feedback
GSA continue to enjoy a close working relationship with Corus Construction & Industrial.

The Client
PDVSA is the state owned refining company, operating one the largest refining complexes in the world.

The Challenge
The client approached GSA to develop a Basic Engineering Package for a process to extract Vanadium from the High Vanadium (HV) Flexicoke generated at the existing Amuay Refinery.

The Solution
To provide an integrated Multi Discipline Basic Engineering Package following PDVSA's client and international standards where applicable. The design was broken down into the following areas, Ferrovanadium, Hydrometallurgical, Pyrometallurgical and Utilities. The design for these area's were based around the integration of an existing DCS system with the exception of the Ferrovanadium area which had to be designed on a stand alone control and operational basis. With input from other disciplines the documents the E, C&I department provided resulted in over 6400 man hours, over 28000 man hours in total for the project.