Breathing New Life into Aging Infrastructure: Emergency Generator Control Panel Upgrade in Qatar

Every process plant relies on a robust emergency power system. But what happens when the control panel governing your backup generator becomes outdated? This was the challenge faced by a client in Qatar, operating with a 30-year-old emergency diesel generator (EDG) control panel.

Challenges and Planning

Petrotec’s team faced a unique set of obstacles:

• Obsolete Technology: No original equipment manufacturer (OEM) support existed, and most internal components were unavailable.
• Limited Information: Decades of operation meant limited access to original drawings.
• System Complexity: The panel interfaced with numerous systems, including LV switchgear, fire alarms, and a UPS.
• Minimal Downtime: The client required a solution with minimal disruption to their critical operations.

Our Approach

Through meticulous planning and collaboration, Petrotec navigated these complexities:

• Comprehensive Site Assessment: Our team, along with the proposed controller OEM, visited the client to assess the situation firsthand.
• Technical Expertise: We provided in-depth technical discussions, addressing the client’s specific concerns regarding the generator and its accessories.
• Modernization with Integration: The old panel was replaced with a cutting-edge Woodward generator controller and Siemens PLC/HMI system, ensuring compatibility with existing infrastructure.
• Detailed Design and Coordination: New drawings were meticulously created, reviewed, and coordinated with various vendors.
• Rigorous Testing: A successful Factory Acceptance Test (FAT) ensured the system functioned flawlessly before installation.

Overcoming On-Site Hurdles

Despite thorough planning, on-site challenges arose:

• Limited Access: Identifying cables prior to shutdown was a critical yet difficult task due to limited accessibility.
• Adaptability: New client requirements emerged, such as generator load testing and interface functionalities.
• Shutdown Delays: The original shutdown schedule faced postponements due to unforeseen circumstances.

Delivering a Reliable Solution

Petrotec’s team displayed exceptional adaptability and problem-solving skills:

• Phased Implementation: Recognizing the need for flexibility, we replaced the panel and conducted initial tests during a partial shutdown.
• Collaborative Teamwork: We worked closely with the EPC contractor and various client departments to ensure a smooth execution.
• Technical Expertise: The team addressed new site requests, including generator load testing, interface integration, and system operation demonstrations.

Outcomes and Success

The project culminated in:

• Modernized Control System: The obsolete panel was replaced with a state-of-the-art system, ensuring reliable and efficient emergency power management.
• Improved Plant Efficiency: Integration with existing systems facilitated seamless operation and enhanced overall plant efficiency.
• Enhanced Operational Safety: The upgrade ensured a more robust and reliable emergency power supply, contributing to improved plant safety.

Upgrading aging infrastructure can be a complex undertaking. This project demonstrates Petrotec’s commitment to providing innovative solutions for challenging industrial automation tasks in Qatar. Our expertise in emergency generator control panel replacement, coupled with a collaborative approach, ensures a successful and efficient outcome for our clients.