Grupo Miesa carried out the complete migration of the control system and the MCC responsible for crude oil pumping on a strategic pipeline in the Caribbean. The original system, in operation for more than 17 years, consisted of variable frequency drives, SMAR controllers and a Foundation Fieldbus (FF) instrumentation network.
- 17+years in service of the system replaced
- S7-400Hredundant controllers
- 315 kWlargest drive (plus 11 and 132 kW)
- 10 kWUPS in the control room
Field instrumentation
The existing Foundation Fieldbus instrumentation was reused and new ATEX-compliant equipment was added. In the classified areas, ET 200iSP remote I/O and SIMATIC Compact Field Units (CFU) were used, connecting the field devices through digital protocols.
Control and supervision system
- Siemens PCS 7 DCS with an engineering station and an operator station
- Redundant S7-400H controllers for harsh environmental conditions (IEC 60068-2)
- Redundant fibre-optic ring network with Media Redundancy Protocol (MRP)
- SIPLUS equipment in control and communications wherever possible, due to the aggressive environment: sulphur, salinity, humidity and high temperatures
- Direct integration with drives, the MCC and intelligent field devices
Drives, safety and control room
- Replacement of the variable frequency drives with new 11 kW, 132 kW and 315 kW units
- Emergency Shutdown System (ESD) to IEC 61508, with shutdown logic and dedicated safety elements; safety logic integrated in the DCS to SIL 2/3 (IEC 61511)
- Complete refurbishment of the control room: lighting, air conditioning, technical furniture and a 10 kW UPS
Result
An obsolete system has been transformed into a modern, scalable platform, with redundancy in controllers, networks and stations, real-time monitoring of pump vibration, temperatures and efficiency, and operator stations with a clear, standardised interface. Miesa was responsible for detailed engineering, programming and commissioning in an environment with demanding safety requirements (ATEX, SIL).