Badger Midstream’s Grey Badger site in Panhandle, Texas is a cryogenic gas processing and treatment plant. Initial capacity of the plant is 25,000 Mcf/d. It has four miles of steel NGL pipeline and 4.5 miles of 8’ steel high pressure residue pipeline. The plant is an ultra-high recovery cryo plant with ethane rejection capability, amine treating, nitrogen rejection, helium recovery, and condensate stabilization.
The company sought an HMI/SCADA solution to control all the processes of the Grey Badger gas plant including plant metering, compression monitoring, tank/pump/valve control, and the monitoring and control of 105 proportional-integral-derivative (PID) control loops. The new solution would replace an existing system based on a combination of two competitor products due to lack of support of their installed product versions and comparatively high costs of upgrades and yearly/ongoing maintenance charges. Understandably, Badger wanted their new solution to be more cost-effective and easier to maintain.
The selected HMI/SCADA would need to integrate with the plant’s DeltaV DCS control, Allen Bradley controllers, Emerson OPC Server, and various electronic flow meter (EFM) remote terminal units (RTUs), as well as with various plant equipment including heaters, dehydrators, vapor recovery units, separators, heat exchanges and more.