Restoring Automated Batch-Temperature Control

Restored safe automated steam temperature control to a high-margin reduction process that had been operating manually on degraded piping and failing valves.

Reduced batch-loss risk, operator burden, steam-leak exposure, unsafe manual throttling, and non-code repair risk.

The reduction process had been in complete disrepair with nonfunctional batch temperature control for more than 10 years, operator manual throttling, uncontrolled overnight temperature events, valve wear, pipe erosion, steam leaks, and non-code repairs requiring demolition.

Coordinated replacement of the failed steam system, assigning mechanical fabrication and installation to mechanical contractor and controls/system design and startup to controls integrator. Scope included steam piping and bypass/diffuser loop, UDC 2500 controllers, valve supplier V150 3-inch valves with 2052 actuators, instrumentation supplier RTDs, a stainless control panel, 120V control power, wiring, actuator-air and condensate interfaces, insulation and commissioning/testing, with a planned four-to-six-week outage.

Planned outage window of four to six weeks.

Coordinated the reduction-system repair to restore safety and controllability, using a four-to-six-week planned outage and a $99,856.86 option-study estimate comprising mechanical contractor's $58,556.86 mechanical scope and controls integrator's $41,300 controls/startup scope.

option-study estimate; mechanical contractor; controls integrator;4-6 week outage.

Coordinated mechanical contractor mechanical fabrication/installation and controls integrator controls/system design and startup for the steam-piping, control-valve, temperature-controller, RTD, wiring and insulation retrofit.

Improved process safety and controllability by restoring steam delivery and automated batch-temperature control.

Improved process safety and controllability by restoring automated temperature control and eliminating manual steam throttling on degraded piping.

Project scope and individual work packages are presented separately; project totals are not additive to their component values.

Restored automatic temperature control and eliminated manual steam throttling within the documented repair boundary. The option-study estimate and outage plan were planning inputs, separate from final project actuals.

1 detail rows; 250 K project-family value.

Steam Distribution and Batch-Temperature Control

• Project Ownership

  Full lifecycle project ownership

  Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.

• Mechanical Contractor

  Supplier Participation

  Vendor Contribution

  Performed the reduction-system mechanical fabrication and installation scope.

• Controls Integrator

  Supplier Participation

  Vendor Contribution

  Provided reduction-system controls/system design and startup.

Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.

Investigated retrofit alternatives and coordinated piping repair, insulation, control valves, RTDs and commissioning. Restoring automated temperature control linked mechanical integrity with process safety and consistent operation, replacing the need to manage temperature through manual steam throttling.

• Commissioning, Qualification, Acceptance, and Turnover — Application ReviewCapability application review
• Construction Management and Construction Project Delivery — Application ReviewCapability application review
• Control Panels, BOMs, Fabrication, and Shipment — Application ReviewCapability application review
• Instrumentation, Measurement, and Standards — Application ReviewCapability application review
• Mechanical, Piping, Pumps, and Process Interfaces — Application ReviewCapability application review
• Pasteurization and Thermal-Process Controls — Application ReviewCapability application review
• Procurement, Contracts, and Supplier Coordination — Application ReviewCapability application review
• Steam, Boilers, Condensate, and Heat Recovery — Application ReviewCapability application review
• Workstream, Portfolio, and Stakeholder Leadership — Application ReviewCapability application review