PVC DCS UPGRADE PROJECT – BENCHMARK ACHIEVEMENT

Yokogawa Engineering Asia

Yokogawa Systems & Solutions Users Group ConferenceCopyright © Yokogawa Engineering Asia Pte LtdOctober 2003

PVC DCS UPGRADE PROJECT – BENCHMARK ACHIEVEMENTPRESENTED BY:Rashesh M ShahProject Leader10-11th May 2004


About Petrokemya About PVC Plant About PVC Process Existing Systems Why to Upgrade? How to Upgrade? What to Upgrade?

System Sizing System Configuration Major Challenges Strategies to meet Chall

enges Major Surprises Significant Achievement

s Acknowledgements


About Petrokemya Petrokemya is wholly owned SABIC

company producing Petrochemicals and Polymer Resins

Petrokemya facilities have Olefins (Olefins-1, 2 and 3), PVC/VCM, Polystyrene and Polyethylene Plants in addition to Utilities and Steam Generation

Petrokemya facilities have Installed capacity of about 5.15 Million Tons Petrochemicals per Year


About PVC Plants PVC Plant operates Trains - A and B installed

in 1986 with capacity of 100,000 MTY each PVC Plant operates Trains - C installed in

1991 with capacity of 100,000 MTY PVC Plant operates E-PVC installed in 1995

with capacity of 24,000 MTY PVC Plant (Train-A and B) De-Bottlenecking

was completed in 2003 to have additional 40% capacity


About PVC Process PVC manufacturing is a BATCH process Basic Raw Material is VCM which is produced by Ethylene and

Chlorine Petrokemya manufactures K67, K70 and K57 grades of S-PVC

products Petrokemya manufactures P701, P702 and P703 grades of E-

PVC products Application for K67 is General purpose (pipe, conduits,

Furniture etc.) Application for K70 Flexible purpose (mainly electrical cable) Application for K57 Tough plastic (pipe fittings etc.) Application for E-PVC is fine coating (Vinyl Flooring, Wall Tiles,

Artificial Leather etc.)


Existing Systems Foxboro SPEC200 based Analog Control

System for Continuous Control HIMA PLC for Discrete Control and Plant

Shutdown MODCOMP Classic II/75 Process computers

for Batch Application and Data Collection Foxboro INTERSPEC for Analog Signal

Interface to MODCOMP Process Computers


Existing Systems 09 Foxboro SPEC200 I/O Rack and Marshalling

panels (Each 4.0 M Wide) 16 HIMA PLC System and Marshalling Panels

(Each 4.0 M wide) 06 Dryer Room I/O and Control Panels 16 MODCOMP Process computer Panels 05 MODCOMP HIMA Interface Panels 31 Operator Control Panels

(Each 1.0 M Wide) 06 Operator Control Desks


Why to Upgrade ?

Are the Systems Obsolete?

YES…System was installed in 1986 Foxboro SPEC200 nest cards were obsoleteMODCOMP Process computer was obsolete


Why to Upgrade ?Are the Systems Obsolete? Does System have expansion capacity?

NO…Foxboro SPEC200 panel space were occupiedHIMA PLC (for some units) capacity was fully utilized System did not have capacity to accommodate PVC De-Bottlenecking


Why to Upgrade ?Are the Systems Obsolete? Does System have expansion capacity? Are we going to improve Operations?

YES…

Relocated existing Train-A/B Control room to create single common PVC Control roomRemoved Operations from separate Dreyer Satellite Control roomFuture plan for Single Operator for both Trains A and B


Why to Upgrade ?Are the Systems Obsolete? Does System have expansion capacity? Are we going to improve Operations? Are we going to produce more?

YES…

Application Software Optimization resulted in to smaller Batch time and higher productionReduced Downtime resulted in to increased production


Why to Upgrade ?Are the Systems Obsolete? Does System have expansion capacity? Are we going to improve Operations? Are we going to produce more? Are we going to improve Safety and Reliability?

YES…

Critical Rotating Machines (Refrigeration Compressors) shutdown configured to ESD SystemEmergency Short Stop for Reactors configured to ESD System


How to Upgrade ? Shall we involve Consultant or Engineering company?

NO…Petrokemya decided to use in-house resources from Plant Engineering, PVC Operations and Control System Maintenance to form a TEAM to execute the Upgrade Project


How to Upgrade ? Shall we involve Outside Consultant or Engineering Company? Shall we involve PVC Process licensor?

YES…Petrokemya decided to use PVC Process Licensor to develop Batch application and PVC De-Bottlenecking Integration


How to Upgrade ? Shall we involve Outside Consultant or Engineering Company? Shall we involve PVC Process licensor? Shall we upgrade with the same manufacturer?

NO…Petrokemya decided to go for Open Bidding Process to take advantage of latest technology and Vendor Support


How to Upgrade ? Shall we involve Outside Consultant or Engineering Company? Shall we involve PVC Process licensor? Shall we upgrade with the same manufacturer? Shall we execute Upgrades during plant ATA?

YES…Petrokemya decided to execute Upgrades during plant ATA with PVC De-Bottlenecking Project


What to Upgrade ?Conduct Feasibility Study

Task Force was formed to conduct detailed Feasibility and Reliability study to identify all the System components that needs Upgrade


What to Upgrade ?Conduct Feasibility Study Conduct Safety and Risk Analysis

Task Force was formed to conduct detailed Safety and Risk Analysis and identified ESD System requirements, Gas Detection, VCM Detection and Fire/Deluge System Upgrades


What to Upgrade ?Conduct Feasibility Study Conduct Safety and Risk Analysis Shall we install Management Information System?

YES…It was decided to install Process Management Information System for Operations Management, Data Gathering and Reporting


What to Upgrade ?Conduct Feasibility Study Conduct Safety and Risk Analysis Shall we install Management Information System?Shall we install Process Simulators?

YES…It was decided to install Process Simulators for Operator Training, Process Modeling and Testing Process Modifications


System Sizing – DCS and ESD System DI(I) DI DO(I) DO AI(I) AI T(I) T PI(I) AO(I)

Unit 21 126 14 81 0 29 0 14 0 11 28 Unit 22 97 44 41 28 16 0 6 0 10 14 Unit 23 3 7 3 0 7 9 8 0 4 8 Unit 24 687 3 374 2 70 12 111 0 20 62 Unit 25 157 8 70 0 18 0 2 0 0 5 Unit 26 86 0 52 0 24 14 12 0 0 10

Unit 27-Main CR 0 106 41 10 0 1 0 0 2 2 Unit 27-Dryer CR 0 4 0 4 0 26 0 29 4 11

Unit 28 126 124 88 70 0 0 10 0 0 0 Unit 39 0 154 44 4 0 23 0 72 0 5

Unit 54-Mian CR 0 283 132 5 5 0 0 0 10 0 Unit 54-Dryer CR 0 0 0 0 2 3 0 0 8 0

Unit 60 0 0 0 0 13 0 5 0 1 0 Unit 63-Anlayzer House 4 58 0 39 0 0 0 0 0 0

Unit S41-Substation 0 429 0 418 0 0 0 0 0 0 Unit 41-VCM Area 0 45 0 0 0 0 0 0 0 0

Sub-Total (Actual) 1286 1279 926 580 194 88 168 101 70 145

Active Spares (10%) 129 128 93 58 19 9 17 10 7 15

PVC De-Bottlenecking 257 256 185 116 39 18 34 20 13 29

ESD Systems 95 60 48 38 24 0 12 0 5 12

Sub-Total 1767 1723 1252 792 276 115 231 121 95 201

5534 (84 %) 1039 (16 %) Grand Total 6573


System Configuration

Adobe Acrobat Document


System Hardware

06 FCS System Panels 06 HIS (Closed Console Type) Operator Consoles 06 Analog Interface Panels (1.8 to 2.4 M wide) 15 Digital Interface Panels (1.8 to 3.6 M wide) 01 Remote I/O Panel 03 Auxiliary System Panels 02 Power Supply Distribution Panels 02 ESD System Panels 04 ESD Marshalling Panels 01 Bentley Nevada VMS Panels


System Hardware

02 EXAOPC Servers 02 Engineering Work Station (for DCS) 01 Engineering Work Station (for ESD) 01 SOE Work Station (for ESD) 01 Supervisory Work Station 01 PIMS Server 10 PIMS Clients 03 HIS Stations for Simulator System 01 Engineering Work Station for Simulator System 01 CAPE Simulator station


Major Challenges Cut-over the entire system and integrate with PVC DBN

project in just 14 days

Management provided window of 14 days during ATA to make system up and running including new addition of PVC DBN Project

It was very challenging considering the fact similar task would take

not less than 21 days as per industry norms


Major Challenges Cut-over the entire system and integrate with PVC DBN project in just 14 days Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process

Licensor

PVC DBN Project, Batch Process Software Enhancement and Lack of Pseudo-codes for MODCOMP programs were driving force to involve Process Licensor, Oxy-Vinyl for Application Software Development


Major Challenges Cut-over the entire system and integrate with PVC DBN project in just 14 days Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor Lack of Pseudo code or Logic Narratives for MODCOMP Batch programs and HIMA Logic

For some reasons, Plant did not have these very vital documents to understand basis of application and subsequent approval of new application development


Major Challenges Cut-over the entire system and integrate with PVC DBN project in just 14 days Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor Lack of Pseudo code or Logic Narratives for MODCOMP Batch programs and HIMA Logic Lack of Ferrules/Tags on each and every wires

Unbelievable but true…

None of the wires in the plant, whether in field JB or Control room had Ferrules/Tags on themSince It was require to disconnect and re-connect more than 16,000 wires in control room it could create real chaos!!


Major Challenges Cut-over the entire system and integrate with PVC DBN project in just 14 days Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor Lack of Pseudo code or Logic Narratives for MODCOMP Batch programs and HIMA Logic Lack of Ferrules/Tags on each and every wires As-Built condition of Plant Wiring

Even though Plant documentation is updated regularly, about 18 years of Plant Operations and Hundreds of Plant Modifications calls for exact mapping of plant conditionsWe were not prepared to take even smallest of chance which could cost us a lot later


Major Challenges Cut-over the entire system and integrate with PVC DBN project in just 14 days Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor Lack of Pseudo code or Logic Narratives for MODCOMP Batch programs and HIMA Logic Lack of Ferrules/Tags on each and every wires As-Built condition of Plant Wiring Integrate with existing Electronic HIMA MCC Modules

VCM Upgrade gave us hard lesson when apparently simple interface turned out to be CRITICAL during start-up


Strategies to meet Challenges TEAM Concept

Petrokemya team consisted members from Engineering, Operations and Maintenance

Project team consisted members Petrokemya, Yokogawa and Oxy-Vinyl


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN

Considering two major modifications, PVC DBN and DCS Upgrades, engineers working on both the projects were common to have very close integration


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN Reverse Engineer MODCOMP Batch Programs and HIMA Logic

Reverse Engineering was performed to create Pseudo-code and Logic Narrative documents.These documents were thoroughly reviewed and approved to bench mark Batch application software development.


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN Reverse Engineer MODCOMP Batch Programs and HIMA Logic Pre-FAT Hardware at Early Stage of the project

One (1) typical of each type of cabinets were fully assembled and wired to inspect layout, accessibility, labels, ferrules etc. to avoid any major changes after mass production.


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN Reverse Engineer MODCOMP Batch Programs and HIMA Logic Pre-FAT Hardware at Early Stage of the project Comprehensive Operators/Technicians and Engineers Training

Target Simulators and actual application software used for comprehensive Operator Training


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN Reverse Engineer MODCOMP Batch Programs and HIMA Logic Pre-FAT Hardware at Early Stage of the project Comprehensive Operators/Technicians and Engineers Training Joint Prototype Software Development

Prototype software was developed and rules were defined for developing application to have consistency in look and execution


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN Reverse Engineer MODCOMP Batch Programs and HIMA Logic Pre-FAT Hardware at Early Stage of the project Comprehensive Operators/Technicians and Engineers Training Joint Prototype Software Development Actual testing with existing Electronic HIMA MCC Modules

Specific Isolators were required to be used to Interface with existing HIMA MCC modules as it can source only 3 mA current.


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN Reverse Engineer MODCOMP Batch Programs and HIMA Logic Pre-FAT Hardware at Early Stage of the project Comprehensive Operators/Technicians and Engineers Training Joint Prototype Software Development Actual testing with existing Electronic HIMA MCC Modules Wireman Interviews

Skilled wireman were selected considering extremely tight schedule of re-termination during ATA.


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN Reverse Engineer MODCOMP Batch Programs and HIMA Logic Pre-FAT Hardware at Early Stage of the project Comprehensive Operators/Technicians and Engineers Training Joint Prototype Software Development Actual testing with existing Electronic HIMA MCC Modules Wireman Interviews Loop Check from Junction Boxes

Waiver to plant procedures was granted to check loops from JB instead of field element to gain on schedule without affecting functionality


Strategies to meet Challenges TEAM Concept Common resources for DCS Upgrade and PVC DBN Reverse Engineer MODCOMP Batch Programs and HIMA Logic Pre-FAT Hardware at Early Stage of the project Comprehensive Operators/Technicians and Engineers Training Joint Prototype Software Development Actual testing with existing Electronic HIMA MCC Modules Wireman Interviews Loop Check from Junction Boxes Integrated FAT at Jubail Staging Area

Total System components, including third party subsystems, were assembled and Integrated FAT was carried out at Jubail staging area using target application software.


Major Surprises

UPS Power Capacity

During Detailed design it was discovered that UPS power capacity, after upgrades do not maintain spare capacity margin requirements.We decided to upgrade existing UPS system


Major Surprises

UPS Power Capacity Early Test Commissioning for PVC DBN Compressor System

During Installation phase of the DBN project, Management decided to Test commission new refrigeration Compressor system.The team worked together to install ‘temporary’ set up to install DCS/ESD and Vibration monitoring system to achieve the objective.


Major Surprises

UPS Power Capacity Early Test Commissioning for PVC DBN Compressor System Impact due to Iraq Conflict

Material Delivery and Shipments affected but fortunately overall schedule was unaffectedDue to high alert, Personnel from Oxy-Vinyl did not participated in FAT


Major Surprises

UPS Power Capacity Early Test Commissioning for PVC DBN Compressor System Impact due to Iraq Conflict Impact due to SARS in Far-East

Yokogawa personnel from Singapore could not travel as scheduled However, Yokogawa managed to send some personnel from Philippines and fortunately overall schedule was unaffected


Major Surprises

UPS Power Capacity Early Test Commissioning for PVC DBN Compressor System Impact due to Iraq Conflict Impact due to SARS in Far-East Damage of the Existing System cable

During Installation phase, One of the existing system cable was damaged and resulted in to loss of monitoring display of some unit of the plant under operation.Investigation revealed that cable was not ‘cut’ but some cores were shorted apparently during installation of the system cables.Incident compelled us to


Significant Achievements

Changeover of the system 5 days ahead of schedule

System was installed, tested and commissioned within 9 days (instead of 14 days as planned and 21 days as per industry norms)

MESSAGE FROM IBN-HAYYAN PRESIDENT…-----Original Message-----From: Wabli-Al, Abdulaziz A. Subject: RE: PVC DCS Upgrade Project_Mechanical Completion Notice

This is a remarkable achievement. Good planning, execution, and determination paid up again. Well done guys, and many thanks to all who were involved in this job .

Best Regards,

aaw



Changeover of the system 5 days ahead of schedule Smooth changeover without any undesired incidents

Perfect Safety RecordNo Operational Mal-function or tripMore than 18,000 wires cut, ferruled and terminated with extremely high accuracySmooth commissioning of every UNIT of the plant



Changeover of the system 5 days ahead of schedule Smooth changeover without any undesired incidents Significant Operational and Plant Efficiency Improvements

Downtime reduced significantlyBatch software Enhancement resulted into increased productionOperational savings by integrating dryer operations in main control room


Acknowledgement

YOKOGAWA is Committed PARTNER, Just not only VENDOR Appreciation to YEA (Yokogawa Engineering Asia) Appreciation to Yokogawa Middle East (YME) Appreciation to Oxy-Vinyl (process Licensor) Appreciation to Olayan Descon (Contractor) Petrokemya Team Members (PLE, PVC Operations, CSD Maintenance, Electrical, Analyzer and Safety)


TEAM SPIRIT, POSITIVE ATTITUDE TOTAL COMMITMENT ARE SECERETS

OF PVC DCS UPGRADE PROJECT SUCCESS


Contact Details

Rashesh M ShahPetrokemya, PLE Department,PB # 10002, JUBAIL, 31961, KSA

Tel # 357-7625Fax # 358-2056Email # [email protected]


THANK YOU

Documents

PVC DCS UPGRADE PROJECT – BENCHMARK ACHIEVEMENT