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Emerson’s migration engineering services and DeltaV Connect technology have enabled Groupement Berkine to upgrade an aging oil-field site control room without any downtime or lost production.

The company has estimated that the work on the control room at the Hassi Berkine South oil-field site in the Berkine Basin, south east Algeria, saved Groupement Berkine USD25m (GBP15m) over a conventional solution.

The existing Bailey human-machine interface (HMI) system at Hassi Berkine was aging and the ongoing maintenance costs – due to the limited availability of parts and dedicated maintenance resource – were projected to be unacceptably high.

The consoles are critical to the smooth running of the plant and any failure could have caused an unscheduled shutdown resulting in a loss of production.

The main challenge for Groupement Berkine was to replace the existing HMI system without requiring any downtime, which would cost the plant around USD25m per day in lost production.

It was also essential that the upgrade would not have a detrimental effect on the DCS running the plant.

The existing legacy Bailey consoles and more than 800 extensive graphic displays were migrated to DeltaV workstations over a nine-month period.

Emerson was awarded the contract to upgrade the HMIs because it was able to meet every technical requirement required by Groupement Berkine including compatibility with the existing Bailey INFI 90 DCS, a single system database for all the oil treatment lines, a 10-year guarantee for the lifecycle of equipment, as well as engineering services and after-sales support.

Emerson’s DeltaV Connect Solution for Bailey systems was used to seamlessly connect new DeltaV operator stations with existing Bailey controllers and I/O.

The DeltaV Connect Solution is an interface designed to communicate with tags in the Bailey process control units so that operators perform the same tasks from DeltaV Operate workstations as they did from the Bailey consoles.

The system installs and starts up with no downtime, enables redundancy, and requires no modifications to the Bailey DCS.

The existing Bailey INFI 90 DCS contained more than 16,000 tags that all needed to be migrated and commissioned while the plant remained online.

More than 800 graphic displays had to be designed to closely match the existing screens in order to minimise any operator training difficulties during the switchover.

Combining the expertise of Emerson’s engineering staff with the use of an automated conversion utility, it was possible to generate DeltaV operator interface displays with the same primary objects, layout, and toolbars for one-click navigation to other displays.

Using Emerson’s engineering services it was possible to reduce the time, effort and risk associated with the display development.

Emerson also provided Groupement Berkine with services to generate Bailey console tag database conversions for immediate use in the DeltaV Connect solution.

The database conversion generated 100 per cent of the modules needed in the DeltaV Connect solution interface.

Emerson personnel oversaw and checked all the conversions.

This process, and particularly the automated conversion tools, reduced the opportunities for error during interface configuration.

Two months before the final migration, two workstations and one DeltaV Connect server were installed for operator training and process simulation.

The DeltaV simulation capability provided a multi-node training system on site to get operators familiar with the process before it went online.

This guaranteed that the change-over was as smooth and efficient as possible.

To handle the important scope of the total inputs and outputs, Emerson installed two redundant servers with the DeltaV Connect licence with 10,000 tags each.

The DeltaV based architecture eventually included eight control room workstations, three remote workstations located in technical rooms, two DeltaV Connect redundant servers, a server professional, and a data historian.

During the migration phase of the project, the individual Bailey consoles were turned off at four-hour intervals, enabling possible anomalies to be identified and to ensure a smooth transition.

Emerson Process Management

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