Shell commits $32 million to Emerson for major automation projects at Deer Park refinery

PlantWeb architecture and FOUNDATION fieldbus technology to be used in critical refinery applications for Shell Deer Park, the fifth largest refinery in the U.S.

Emerson Process Management has received a $32 million commitment for a refinery automation program from Shell Deer Park Refining Company (SDPRC). Emerson will perform front-end engineering and design (FEED) and project execution services as main automation contractor (MAC).

The initial phase, valued at $12 million, calls for the installation of Emerson's PlantWeb digital plant architecture with FOUNDATION fieldbus technology to upgrade the instrumentation and controls for Shell's large 67,500 bpd (barrels per day) fluid catalytic cracker (FCC) unit and associated gas plant facility in Deer Park, Texas. Catalytic cracking is a high value-add petroleum refining process where intense heat, low pressure, and powdered catalyst are used to accelerate the chemical reaction required to manufacture gasoline.

Engineering is already under way, with initial startup of the new instrumentation and automation system scheduled to begin in October 2002. The upgrade to Emerson's FOUNDATION fieldbus instrumentation will be via a "hot cutover," in which the process will continue operating without interruption.

SDPRC had previously tested the capabilities of Emerson's DeltaV system and smart field instrumentation using FOUNDATION fieldbus technology at the North Effluent Treater Unit. PlantWeb was an improved way of operating and maintaining the plant—more than what was realized from DCS (distributed control system) technology.

"This project is an important investment for improving reliability and will help us achieve our vision to supply refined products at the lowest total cost," said Stacy Methvin, President & CEO of Shell Deer Park Refining Co. "In addition, Emerson's AMS software works with predictive diagnostics in the field devices to give us increased performance of the process through better optimization of our assets."

"We are extremely pleased that Shell has selected Emerson to automate the catalytic cracker unit and gas plant at Deer Park," commented John Berra, executive vice president of Emerson with responsibility for the process management business. "As a follow-on to the excellent results with the treater facility, our selection as main automation contractor for this major project is another example of our position as a leading, comprehensive supplier for the refining industry."

The initial PlantWeb solution at Shell Deer Park will include a DeltaV digital automation system with AMS predictive maintenance software networked with intelligent field devices such as pressure and temperature transmitters from Rosemount, and Fisher valves with Fisher FIELDVUE digital valve controllers. The open PlantWeb architecture facilitates delivery of process information to users in the plant, including the diagnostics and maintenance information communicated via FOUNDATION fieldbus communications protocol. PlantWeb technology also integrates other plant systems, including connecting, via OPC protocol, the DeltaV system and the new Triconex Protective Instrument/Surge Control System and Bently Nevada vibration monitoring system.

About Shell Deer Park

Shell Deer Park has a crude oil capacity of 340,000 barrels a day (42 gallons per barrel). The refinery assets are owned by the Deer Park Refining Limited Partnership, a 50-50 joint venture formed in 1993 between Shell Oil Company and Petroleos Mexicanos (Pemex). Over the past eight years, the partnership has invested more than $1 billion in refinery upgrades, enabling Shell Deer Park to increase capacity, obtain a reliable supply of crude oil from Mexico, and sell a wide range of refined oil products throughout North America.

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