Project Overview:

Client: Marathon Group Automation Modernization Program, USA
Project: Los Angeles Refinery
Duration: 4 Years

• Location: Various below Locations of Los Angeles Refinery:
• • LAR - Los Angeles Refinery - Completed
• • LARC - Los Angeles Refinery, Carson - Completed
• • LARW - Los Angeles Refinery, Wilmington – Completed
• • LAR1,2,3 and 4 – Ongoing

Objective:

The Marathon Petroleum Corporation (MPC) Los Angeles Refinery Automation Modernization Project (LAR AMP) addresses varying levels of technical obsolescence in the refinery's Basic Process Control Systems (BPCSs), third-party Programmable Logic Controllers (PLCs), and associated thirdparty devices, as well as the fiber communication cabling, patch panels, and networking equipment required to support the new BPCS equipment. The LAR AMP project specifically addresses BPCS migration and standards compliance to be completed as part of the 2024 turnaround or before, with the exception of the HTU-4 turnaround, which has been delayed to 2025.

Project Execution:

The Marathon Group Automation Modernization Project (AMP) is planned and executed in 8 phases (LAR1 to LAR8). Apart from 2 blending projects were completed (LABC and LARBW). In each phase of the project particular area controllers and HMI consoles were picked and upgraded to new Honeywell EPKS R520 console and C300 controllers. Also new safety controllers were added or existing safety controller were modified during each phase in order to comply local government safety standards. This project was executed using 2 teams located in India & US. US team supported the commissioned activities, rest all engineering solutions were provided by India team. The project was overlooked by Refinery’s own project team and EP contractor.

Responsibilities:

• The team was responsible for designing and providing the technical solution for the migration of existing legacy controllers and HMI, by creating standard solutions by means of C300 logic templates and FDS and HMI FDS for ASM compliance.
• The team was responsible for managing technical/schedule/budgetary meetings.
• The team was responsible for testing the migrated software pre-commissioning (CFAT, iFAT) and to provide the training to the end user.
• The team was responsible for commissioning the migrated software
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Technical Solution (DCS)

Final rollout of the system to production environment. Data migration, user training, and go-live support to ensure smooth transition.

• HPM to C300
• PM to C300
• AM to C300
• AM to ACE
• HG (CBs, LEPIU, HLPU) to C300
• HG (DHP) to SCADA
• AB PLC to C300 migration
• Siemens to C300
• TriconCx via SCADA
• AB PLC via PCDI & UDT (EIM)

Safety Management

Comprehensive training programs for end-users and administrators. Documentation and knowledge transfer to ensure proper system utilization.

• Incident analysis & root cause identification
• Corrective & preventive actions
• Safety drills and training
• Culture of process safety

Human-Machine Interface

Ongoing system maintenance, updates, and troubleshooting. Performance monitoring and optimization to ensure continued system reliability.

• GUS to EPKS R520 with ASM
• Native Window to EPKS R520
• EPKS R510 to R520
• PLC HMI Panel to EPKS R520
• Safety graphics based on C&E

Distributed Control System:

Comprehensive project evaluation to assess success metrics, ROI, and lessons learned. Documentation of best practices for future projects.

•  HPM to C300
•  PM to C300
•  AM to C300
•  AM to ACE
•  HG (CBs, LEPIU, HLPU) to C300
•  HG (DHP) to Scada
•  AB PLC to C300 migration
•  Siemens to C300
•  TriconCx Comms link via Scada
•  AB PLC Comms link Via PCDI and UDT (using EIM)
•  Experion® PKS R320: Provided a robust and scalable