DCS
What does 'DCS' stand for?
Distributed Control System
What does 'DVC' stand for?
Digital Valve Controller
What does 'SIS' stand for?
Safety Instrumented System
What does 'MOC' stand for?
Management of Change
What are the four pillars of Motiva culture?
We do the Right Thing
We are One Motiva
We are Empowered
We Deliver Excellence
Tagname
Current mode, not in Normal mode
SP, PV, OP, VP
At Motiva, do flowmeters read standard or actual flow?
Standard
1.5X BONUS:
What is needed to calculate actual flow?
How are SIS instruments most easily identified in the field?
Transmitter caps painted red
Tagged as SIS tested
TRUE/FALSE?
Fuel Gas service control valves and orifice plates are only overhauled once failed
FALSE
1.5X BONUS:
On what frequency are they overhauled?
How many total fresh crude barrels per day does PAMC process?
660MBPD
A flow controller is measuring flow upstream of a control valve.
What control action is necessary to control to setpoint correctly?
If a flow transmitter is ranged 0-100"H2O, 0-50GPM, what will be the engineering unit range if re-ranged to 0-400"H2O?
0-100GPM
SQRT(100"/400") = 50GPM / X
Solve for X
What does 'M' stand for in Motiva's typical SIS nomenclature mean?
Median
1.5X BONUS:
Why do we use the median?
An old pneumatic positioner has failed. The team would like to install a DVC in its place.
How would this get accomplished?
Single Discipline MOC to upgrade
Business team approval for DVC, wiring and labor cost
Control valve bypassed
PSSR once installed and before returned to service
TRUE/FALSE
The first industrial DCS was built in 1959 at the Texaco Port Arthur refinery (now PAMC)
TRUE
This was an RW-300 Computer Console controller implemented by the Ramo-Wooldridge Company at FCCU3 and is in the Smithsonian Institute
What are at least two typical instrument/DCS communication protocols used at Motiva?
Profibus/Fieldbus (Serial), Modbus, 4-20 HART, Honeywell Digitally Enhanced (DE), Open Platform Communications (OPC)
A fail open valve using a 4-20mA signal and a 3-15psig air operating range is requested 25% valve position (output).
What current (mA) and air pressure (psig) is being used?
16mA, 12psig
How long can an SIS bypass be active?
72 Hours
Describe PID, APC, etc controller Uptime and Compliance
How does Motiva monitor PID, APC, etc controller Uptime and Compliance?
Uptime is a measure in percentage of time a controller is in its highest mode
Compliance is a measure in percentage of time that a controller's PV is within a programmed tolerance to SP
MDPro
What is the oldest running unit at PAMC?
VPS2
1.5X BONUS:
What year was VPS2 commissioned?
On the board, draw a typical Motiva fired heater control scheme.
Include instrumentation, control loops, overrides, etc.
Must Include:
Heater Outlet Thermocouple and Temperature Control
Fuel Gas Line, Orifice, Flow Control and Control Valve
Fuel Gas Pressure Tap, Transmitter and High/Low Overrides
O2 Analyzer and Low Override
Explain how a Guided Wave Radar works
Must Include:
Describe how instrument contacts process - guided probe, maybe non-contact radar
What type of signal - low energy microwave pulse down probe, or reflected radar signal
Measures time for signal to reflect from process surface - time domain reflectometry
Can perform interface because signal continues down probe or through space and second signal reflection will occur
What frequency does Motiva test SIS systems?
Is testing performed online or offline?
6 year frequency
Both
Provide three items to be entered in an 80/20 Turnaround scope prior to deadline
Provide three items to be entered in a Scope Input prior to deadline
80/20 - SIS valves via SLM, Fuel Gas service, GHG instruments, DVC Valve Scans, Control Valve Stroke test
Scope Input - CAREs, MOCs, MTAs, APC Needs, SIS Needs, Bad Actors
In 1903, what company was the original owner of what is now PAMC?
The Texas Company