SAMPLE PROJECTS

ELECTRICAL, INSTRUMENTATION & CONTROL SYSTEM

PROJECT AREA

Fort Nelson Gas Plant (Capacity
990 MMSCFD) Control Systems

YEAR

2011-2012

​

​

PROJECT DETAILS

The ABB PCV Operator stations that have been utilized by Spectra Fort Nelson, have been in use at this site for more than fifteen years. During these years, ABB DCS products have evolved with technology,
there have been significant software and hardware changes. The PCV software is now in the Classic Phase of the ABB Product Lifecycle. Spectra Energy has contracted ABB to provide an updated process Control System per Spectra Project Q0677. The evolution strategy chosen by Spectra Energy, Fort Nelson is to migrate from the existing PCV HMI system and to implement ABB’s Symphony Plus System. This project functionally upgrades the existing PCV operator stations to new to a Symphony Plus HMI system for the Fort Nelson facility. Several ABB DCS hardware and software changes are necessary to support the new HMIs. The version of “Symphony Plus” (chosen) was released by ABB in December 2011; it is not field proven, and consequently involves significant unknown risks in implementation and operation.
​
CNGL was assigned to work with Spectra Energy and interface with ABB to efficiently deliver a DCS system that was optimized to the requirements of the Spectra Energy.

Control System upgrade of the Fort Nelson Gas Plant
(PCV HMI System to ABB Symphony plus)
SPECTRA ENERGY

PROJECT AREA

Pine River Gas Plant (870 MMSCFD) – Generator GE3401B

YEAR

2012

PROJECT DETAILS

Assure safe and reliable operation of generator GE3401B, including turbine (Allison 501-KB5), speed reducing gear train (Allen Gear) and generator (Ideal Electric).

The turbine and gearbox had reached their major maintenance interval, and were at risk of failure if not maintained. The gearbox had been subjected to vibration problems since installation. This issue was addressed with the replacement of the gearbox with a re-designed unit. The turbine generator assembly was taken out of service for replacement of the gearbox, and periodic service of the generator and auxiliaries. While the work on the gearbox and generator was in progress, routine inspection and maintenance of the turbine was completed. CNGL was assigned for the Project management, construction coordination, Field engineering and Inspection for this projects and CNGL delivered the project at a highest level of satisfaction on time and on budget

GE3401B generator set (JET-B 40000) overhauling and gearbox replacement.
SPECTRA ENERGY

PROJECT AREA

Kwoen Gas Plant To
SUKUNKA Communication Tower (Near Pine River Gas Plant)

YEAR

2012

PROJECT DETAILS

CNGL was assigned to provide engineering services to design and prepare Construction Work Packages (CWPs) to construct 6.6 km of a single-phase 14.4 kV overhead power line from the Kwoen Gas Plant to the communication tower at Sukunka Junction.

6.2KM, 14.4KV Overhead Power Line from Kowen plant to Sukunka communication Tower along with Grizzly the pipeline - Delivered complete Electrical engineering package that includes High and Medium Voltage
SPECTRA ENERGY​

PROJECT AREA

Shell Carmon Creek SAGD project,
Peace River AB

YEAR

2014 - 2015

PROJECT DETAILS

Review of the Electrical design and drawings.
Field verification for the Electrical Package through site visit to Peace River AB.
Alberta P. Eng stamping on the P&ID, Isometric, piping arrangement and Electrical drawing.
The mechanical stamping is only to verify the material, piping routing, clearances, and supporting are based on the design code.

Alternate Power Systems – Diesel Generator Fuel Distribution System
WAJAX POWER SYSTEMS​

PROJECT AREA

In-Situ Reliability

YEAR

2014 – 2015

PROJECT DETAILS

Screened SAP event logs and operations reports for HIPPS (High Integrity Pressure Protection System failure incidents.
Onsite review of the problematic instrumentation and key data, information collection from stakeholders
Conducted Root Cause Analysis (RCA) on safety valve failures. During the investigation, other shortcomings related to the procedures for regular proof testing of safety system valves were identified
Periodic presentations to operations. Recommendation for updating operating procedure
Drove management of change (MOC) processes for replacement of numerous transmitters. Engineered suitable replacements for the instruments and created construction work packages (CWP) for their replacements
Reviewed SAP maintenance schedules for the tasks related to the proof test interval (PTI) of safety system devices that were part of safety instrumented functions (SIF). Reviewed safety resource specification (SRS) for the list of SIFs and the PTI requirements. The SAP maintenance schedule and procedures were vetted against these requirements. Created equipment strategy data sheets (ESDS) for instruments. This task required some training to understand the Suncor method of developing their ESDSs. An understanding of the Suncor risk matrix and failure modes effects analysis (FMEA) are key components in developing ESDSs.
Reviewed proof tests made on pads at Firebag. Checked against SRS requirements and SAP
maintenance functions. Provided information to safety engineer

HIPPS study, SIL services, Instrument Reliability
and Asset Management
AGRIUM

PROJECT AREA

Handover of Trans-Alta Cogen
Unit to Suncor Energy

YEAR

2016 - 2017

PROJECT DETAILS

Suncor Energy took over an old Co-generation unit from TransAlta that provides power to its base plant in Fort McMurray. A proper reliability and maintenance program, supporting technical documents, are not in proper order.

CNGL Inc is currently engaged to provide technical input in specific to Electrical Instrumentation and control assets in support of all Reliability processes as required by the Integrated Reliability program. CNGL engineers are also contributing and supporting on criticality assessment for specific areas, supporting equipment strategy development process to create, improve and implement equipment reliability programs that mitigates the risks of identified failure mode for each asset. CNGL engineers create equipment Bill of Material, facilitate ESDS development in accordance with Suncor Technical and master data standards.
​
Responsibilities:

Review the ESDS and identify the Action item with Failure mode and reference it to multiple tags
Create and Review the Maintenance Procedure & Check list and revise/update as applicable and develop an action plan to create task list for all applicable tags as identified in ESDS
Provide consultancy for spare parts recommendations on obsolete parts; support/advisory to Criticality and RCM (Reliability Centered Maintenance)workshops
Find the P&ID, SLD and get related information for all Tags
Identify maintenance significant tags/equipment and initiate maintenance significant master tag list
Retrieve all relevant documentation/manuals from CERLL/LL/Mongoose Database/Field Library etc
Identify Spare parts and provide to SCM
Collect spare parts technical information from available manuals/data sheets
Update bill of materials with material masters in SAP
Identify the list of all equipment where task list can be used and how it will reflect for PM plan
Check Maintenance procedure and check sheets for Plant 39 E&I asset, according the IEEE, NETA and Suncor standards
Provide Return on Investment maintenance costs
Lead the E&I Maintenance & reliability efforts development

Reliability and Maintenance Program Planning for a Co-generation Unit
SUNCOR ENERGY
​​

PROJECT AREA

Design, Drafting, As-Building

YEAR

2016-2017

PROJECT DETAILS

Electrical Studies:
CNGL to develop electrical power system model for assess electrical load flow is presented with stepwise approach. The model is further to be tuned from load flow perspective. While the intent of the forgoing is to develop a model to address system load flow, the model that is developed for that particular purpose will also largely be suitable for other power system studies.

3D Scanning, Mechanical , Electrical Design Drafting:
CNGL is conducting 3D Laser Scanning; Updating mechanical, electrical drawings and as-building

Performance Services Audit:
Pre-audit and Audit as the first two processes of Performance Services are phased out as separate projects in Phase 1, 2, and 3, planned at different time frame suitable for Lantic’smanufacturing operation. At each phase, objectives, approaches, deliverables, and requirements are addressed. As the first approach, CNGL requires access to Delta-V configuration data and latest technical documents such as P&ID’s to provide an audit on the Delta-V system during the summer shutdown of the plant. This is a necessary process to facilitate the future audit and control performance optimization. The assignment is also to combine Phase 2 and Phase 3; by doing so it not only can provide a fully planned audit with plant wide cover for high level analysis, but also analyzes in key plant areas that can bring significant benefits, focusing on areas such as extraction,evaporation, and boilers.

Electrical power system model to assess electrical load , 3D Laser scanning, Updating mechanical, Electrical drawings, Performance service audit and optimizing control systems
LANTIC INC (ROGERS SUGAR)​

PROJECT AREA

Carseland Nitrogen Operation

YEAR

2016 – 2017

PROJECT DETAILS

The Minimum Trip Standard (MTS) is an Agrium internal, corporate wide objective intended to provide reasonable process safety protection as an interim measure until the full Process Design Safety Requirements (PDSRs) are developed. The scope of this project will entail developing and implementing corrective action plans for the 21 MTS items site wide. This is a cluster of 21 engineering design projects under one umbrella named MTS.
​
CNGL Scope of Work:
To address the existing gaps the MTS at CNO
Identify and mark-up P &ID, design and implementation and program changes associated with Triconex
PLC and Foxbro DCS
Execute the necessary field activities and logic changes to meet the MTS requirements with an acceptable level of redundancy and reliability at the CNO site
Development and/or update of associated Functional Logic Diagrams
Development and execution of Full Function Testing (FFT) Procedures
Cause and Effect Matrix update for all of NH3 and Urea Area from existing Triconex files
Field Installation of Transmitters, Actuators and control valves.
Employed “ InTools” for all instrument wirings
​​
Deliverables
Develop a Design Basis Memorandum Document (DBM)
Develop a Class 3 (-15to +30%) total project cost estimate
Develop mechanical, piping, and E&I Work Packages.
Develop and provide Functional Logic Diagrams for applicable scope
Develop and provide CV & MV, actuator and transmitter data sheets and sizing calculations
Develop and provide Cause and Effect Matrix for NH3 (Option)
Develop and provide Cause and Effect Matrix for Urea (Option)
Piping stress analysis and design piping supports as required
Develop and provide a QA/QC plan, complete with Inspection Test Plans (ITPs) that has been approved by Agrium’ inspector and QC turnover package
Confirm CRN and/or ABSA Regulatory requirements
All required CWPs

Minimum Trip Standard Execution Project
AGRIUM​

PROJECT AREA

Carseland Nitrogen Operation

YEAR

2016 - 2017

PROJECT DETAILS

A new Schneider QV3 Quad Voter panel was purchased by Agrium to replace the existing trip solenoid on the Urea C-101 CO2 Compressor. The new QV3 panel was to be located in place of the existing C-101 local control panel. The existing control panel was relocated and equipment on the existing control panel was reconnected. The QV3 panel was to be installed and tied in during the planned June 2017 turnaround. Agrium plans to install cabling pre-turnaround.
​
​
CNGL’s scope of work:
To design and specification of the connection spools between the QV3 and C-101 including passivation requirements.
Design of new cabling to the QV3 and cabling
Relocation of the existing C-101 local control panel including
re-connection of gauges
Integration of the QV3 into the Triconex system
Generation of the necessary full function testing documentation

Provide Engineering Services for CNO C101 Trip Solenoid Project
AGRIUM​

PROJECT AREA

Handover of Trans-Alta Cogen
unit to Suncor Energy

YEAR

2016 - 2017

PROJECT DETAILS

Suncor required technical input in specific to Electrical, Instrumentation and control assets in support of all Reliability processes and to participate and support on criticality assessments for specifics areas, Also to support equipment strategy development process to create, improve and implement
equipment reliability programs that mitigate the risks of identified failure modes for each asset.

CNGL’s Scope of work included (but not limited to):
Review the ESDS; Identify the Action item with Failure mode and reference it to multiple tags; Create and Review the Maintenance Procedure & Check list; Revise/update as applicable; Develop actionplans to create task list for all applicable tags as identified in ESDS;
Provide consultancy for spare parts recommendations on obsolete parts;
Support/advisory to Criticality and RCM (Reliability Centered Maintenance) workshops; Find the SLD and get related information for all Tags;
Identify maintenance significant tags/equipment and initiate maintenance significant master tag list;
Check Maintenance procedure and check sheets for the Plant E&I assets, according the IEEE, NETA and Suncor standards;
Provide Return on Investment maintenance costs; Lead the E&I Maintenance & reliability efforts development

Reliability and Maintenance Program Planning for T&D Reliability and Electrical Engineering Project Team
SUNCOR ENERGY

PROJECT AREA

CS-03 Compressor Station

YEAR

2016-2017

PROJECT DETAILS

Electrical Studies:
​
Enbridge’s Compressor CS03, the existing HPS lights in Compressor Station-3 were old  and inefficient and the current illumination level in the building which seem much lower than the required level.
There was a combination of issues which deem the current lighting system to be inadequate, low luminous and apparently spaced far apart, considering the current actual lumen of each of the existing HPS lights.
The unit used to have an exhaust leak covering the building internal walls and ceiling with soot that has affected the integrity of the lighting system
​
CNGL's Scope of Work:
​

CNGL has conducted option evaluation to find the best solution. The result of this evaluation has led CNGL to redesigning/recalculating the number of required lumens inside the compressor building, replacing the existing/old HPS light fixtures with new LED lights
Provided necessary field commissioning support

CS03 Unit #5 and Fuel Gas Buildings Lighting Upgrade
ENBRIDGE

PROJECT AREA

CS-03 Compressor Station

YEAR

2016-2017

PROJECT DETAILS

Electrical Studies:
​
Enbridge’s Compressor CS03, located next to Highway 97 has a high risk of unauthorized entry into the facility through doors and windows on some buildings those are not protected against intrusion. Many ground level windows, man doors and overhead doors are without sensors or have obsolete beam style sensors installed. Un-protected doors and windows pose an intrusion threat and do not meet minimum-security requirements set out in Enbridge (Legacy Spectra) West standard. This required to remove the existing beam type switches and install new magnetic type switches on each unprotected building man-door, roll-up door and overhead door
​
CNGL's Scope of Work:
​

Existing beam style switches was to be disconnected and unused wiring and conduit to be removed back to nearest pull point. New door switches to be Sentrol magnetic type switches. For classified areas, switches to be model 2807T. For unclassified areas, switches to be GE model 2507A. All un-protected man doors and overhead doors were to have switches installed. Door switches to be wired back to the nearest remote I/O control panel where wires will be tagged and coiled.Wiring to be via conduit or tech cable as appropriate.

CS03 Unit #5 and Fuel Gas Buildings Intrusion System Replacement
ENBRIDGE

PROJECT AREA

Carseland Nitrogen Operation, Alberta

YEAR

2016-2017

PROJECT DETAILS

Electrical Studies:
​
The existing Primary Reformer zirconium oxide style O2 analyzer of Agrium’s CNO plant was an obsolete technology and had been demonstrating reliability issues. Accuracy of the existing analyzer was inhibiting the efficiency and performance of the Primary Reformer.
​
CNGL's Scope of Work:
​
This project was to replace the existing O2 analyzer with a more robust and accurate device and would also include an additional CO/CH4 analyzer. The O2 and CO/CH4 analyzers were to be integrated into the Primary reformer combustion control scheme to enhance firing efficiency and reduce overall emissions.

Deliverables:
​
Generate the purchasing and CWP documentation necessary for the supply and installation of the O2 and CO / CH4 analyzers including full function test documentation CNGL was to provide necessary field commissioning support.

​

Primary Reformer Analyzer (O2 and CO/CH4 )Installation project
AGRIUM

PROJECT AREA

Carseland Nitrogen Operation

YEAR

2016 – 2017

PROJECT DETAILS

In 2017 T/A, Nutrien CNO executed Minimum Trip Standards (MTS) Phase 1 project wherein it has been addressed implementing Process safety interlocks as directed by MTS PDSR for Ammonia and Urea process. Few of these interlocks were implemented as an ad-hoc solution. Due to limitations at the site in terms of time constraints, physical space constraint requiring further evolution of a viable solution and project timeline being too close to the actual T/A timeline, some scopes were not executed.
​
This capital project covers –
a) the scope that got left out during 2017 T/A and now needs to be implemented during 2021 T/A and
b) to enhance the existing MTS interlocks to improve Process safety and operational ease.
​
Hence this Project Objective is to enhance selected interlocks from Minimum Trip Standards (MTS) PDSR to improve Process Safety and overall operation ease.
​
CNGL’s scope of work:
​
Engineering Services and construction work packages for the following
Install an ESDV in 101-E liquid outlet to 109C1A/1B/2A/2B
MDEA Pumps 107-JA/JB and 107-JC/JD Reverse Rotation Protection Valves
MDEA Pumps 107-JA/JB and 107-JC/JD Discharge Flow Meter Addition
Urea Medium/Low Pressure Section High Pressure Transmitter Replacement
Urea MTS Trip Logic End Device HV-3042 Replacement 

Minimum Trip Standard Phase 2 Project
NUTRIEN​

By  CNGL INC