Our Combined Experience

We have listed some of our collective capabilities in an effort to further showcase our experience. They highlight some of our previous control and automation projects as well as some specific project management experience.

Hess Tioga Gas Plant Expansion (Tioga, ND)

Gap Engineering performed the engineering, programming, commissioning and startup for a Honeywell Experion DCS with Honeywell Safety Manager SIS shutdown system. The system contained over 5000 points for both the SIS and DCS systems. The project duration was over 1 year. Prior to the Gas Plant Expansion, Gap provided personnel for the older plant upgrade from TDC3000 and Allen Bradley PLC5 to Experion DCS and Safety Manager SIS.

Total Port Arthur Refinery DHT Units 1&2 Safety System upgrade (Port Arthur, TX)

Gap performed the engineering and programming for a Rockwell Control Logix SIL II SIS project replacing the older Control Logix PLC which was not SIL II to an updated Rockwell Control Logix SIL II controller with additional IO to accommodate the PHA and SRS requirements. This system

Delek Refining Control System Upgrade (Tyler, TX)

Gap performed the engineering and programming for a Yokogawa based upgrade to the UOP CCR unit. A fire destroyed the old system and an exact replacement was no longer available. Gap Engineering provided a turn-key package for the CCR control system (including programming) to duplicate the functionality of the old UOP CCR Lockhopper Control System. Additionally, Gap was involved in project management of the entire CCR I&E rebuild, as well as the programming and integration necessary to incorporate all third party systems into the Yokogawa CS3000 DCS. Gap also provided cutover and startup coverage for the CCR unit (DCS and all associated systems) and was responsible for the coordination of all activities in the CCR during the rebuild on behalf of Delek.

Alon USA (Big Spring, TX)

Gap Engineering provided DCS and I&E support over the course of five years at this 70,000 BPD refinery. Our services here include the Crude Unit DCS upgrade from Foxboro Centum to Experion CS3000, the recent fire rebuild encompassing 50% of the refinery units that needed to be rebuilt or upgraded, and most recently the ULSG and 24 Boiler DCS upgrade projects. Gap functioned as both DCS support and owner’s representatives to help extend the project management capabilities of the Alon Engineering Staff for all projects. During the fire rebuild, Gap provided engineering support for configuration, I&E engineering, managed cutover crews and reported Loop Check status. Gap was also asked to assist with site issues and coordinated the different construction and engineering contractors, reporting all progress and issues to Alon.

Motiva Refining (Norco, LA)

Gap Engineering performed various work at the 240,000 BPD Norco refinery (totaling 4 years) to include: DCS upgrade of 7 units in the Refining East section; from pneumatics and Honeywell TDC2000 to Emerson Delta V DCS and Triconex safety shutdown systems. Gap played an integral role as the owner’s representative for construction as well as provided engineering support for loop checks, Front End Loading (FEL), and Detailed Design Engineering for the Alkylation Unit Triconex System. In addition to this, Gap provided support for DCS and Safety Shutdown Systems FATs and I&E Engineering. GAP was involved in the DCS Graphics development for 6 units in refining east and served as the owner’s representative for the development of an Operator Training System based on the original DCS Configuration and the first principal model. Gap contributed greatly by providing project economics, progress reports and by walking new projects that were started over the 3 1/2 year duration of the DCS Upgrade Projects phase at Motiva for funding approval through the Shell Project Gating System. Gap was also responsible for closing out projects with lessons learned reports, closeout cost reports, and ensured documentation completed and properly filed.

Valero (Ardmore, OK)

Over the course of 2 1/2 years, Gap was involved in the DCS upgrade of 5 refining units from pneumatics and Bailey Infi 90 to Yokogawa CS3000 DCS. GAP functioned as owner’s representative for Valero Ardmore; directing Yokogawa and several engineering companies. In addition to functioning as owner’s representative for I&E construction, Gap was responsible for configuring all Yokogawa DCS systems. Configuration included DCS Graphics, loop testing, on-line module configuration, and operator training.

Engineering Companies (Various Locations)

Often times, engineering personnel is needed to fill in a missing role(s) on a project. Gap understands, and has fulfilled this need for engineering companies such as Honeywell & Mustang Engineering by providing personnel to seamlessly integrate into existing operations for periods ranging from a couple of weeks to a couple of months. For additional information on how we can help you, please contact Gap Engineering.


Specific Project Management Experience (Various Locations)

Chevron Lubricants Plant (Port Arthur, TX)

Gap Engineering’s construction manager worked with the Yokogawa and Chevron teams to replace the existing DCS with a new Yokogawa CS3000 control system, new field instrumentation, new PanelViews, new motors, new motor control centers and new substation equipment that was a result of the entire plant flooding during Hurricane Ike. Areas involved were the east and west tank farms, truck and rail car loading, three packaging lines, equipment rooms and control rooms.

Huntsman Chemical (Geismar, LA)

Gap Engineering provided an automation consultant for CDI Engineering to implement Foundation Fieldbus technology on a new construction project. He reviewed and approved CDI Engineering I&E and control system specifications and procedures.

Motiva Refinery (Norco, LA)

Gap Engineering Personnel served as owner’s representative for Motiva Refining as the construction manager on the Emerson Reinstrumentation projects. Gap Engineering’s extensive experience in the installation of Foundation Fielbus was also very instrumental here.

Shell Chemical (Deer Park, TX)

At Deer Park, Gap Engineering’s personnel served as the Honeywell site manager for the $100MM+ reinstrumentation program on the Phenol II, Cumene and OP3R projects. Scope of work included replacing existing pneumatic controls with new Honeywell (TPS) TDC3000 control system that included all new field instrumentation, hot cut over, commissioning and start up. Some of his responsibilities included managing all site activities to include safety, construction subcontractors, cost, planning, scheduling, quality, customer satisfaction and project administration. All these projects were completed on schedule. In fact, the OPR3 was the first Shell project to receive an Independent Project Analysis (IPA) first quartile rating.

Motiva Refinery (Norco, LA)

Gap Engineering’s Personnel served as the Honeywell site manager for the $70MM refinery reinstrumentation program. Units included the Cat Cracker, Sour Water Stripper, Sulfur Unit 2, Sulfur Unit 3 and the Crude unit. The scope included replacing existing pneumatic controls with new Honeywell (TPS) TDC3000 control system that included all new field instrumentation, hot cut over, commissioning and start up. This scope also included performing a hot cut over of the Safety Shutdown System on the crude unit. Responsibilities included managing all site activities including, safety, construction subcontractors, cost, planning, scheduling, quality, customer satisfaction and project administration. As with the Shell Chemical projects in Norco, this project also required the migration of unit operations to a central control room which included extensive planning and procedures. These projects received the 2002 and 2003 ABC instrument and electrical projects of the year in the State of Louisiana and were completed on schedule and on budget.

BP Refinery (Mandan, ND)

Gap Engineering’s oversaw the construction for the $50MM reinstrumentation program for the entire refinery. This union project scope involved replacing existing pneumatic controls with new Honeywell (TPS) TDC3000 control system that included all new field instrumentation, hot cut over, commissioning and start up. In addition to this, this BP refinery had a power house for electrical power generation. As with all other projects, the project was completed on time and on budget.

Geon Chemical (LaPorte, TX)

Gap Engineering’s Personnel served as the Foxboro site manager for the $25MM reinstrumentation program for the entire chemical plant. The scope of the project included Foxboro I/A installation, hot cut over, commissioning and start up. In this project, Field Enclosures (remote I/O) were utilized instead of marshaling all of the I/O in equipment rooms or control rooms. The project was completed on time and on budget.

Williams Field Service (Bloomfield, NM)

This $20MM union project involved the total reinstrumentation of a gas processing facility. All I/O was cut over hot, and the project was completed on time and on budget.