Project Details
- Onshore Refinery
- 24th March 2023
- Takreer Refining Company
- PLC Upgrade, SCADA System, Automation Retrofit, I/O Mapping
Lemos International successfully executed a comprehensive retrofit of the legacy automation system at an onshore refinery operated by Takreer Refining Company. The project involved upgrading the existing control infrastructure to a modern Allen-Bradley PLC and Wonderware SCADA system, ensuring enhanced reliability, scalability, and operational efficiency. Our scope included I/O mapping, phased migration, installation of new control panels and SCADA servers, and extensive operator training.
Our scope of work included:
- I/O Mapping & Phased Migration: Conducted detailed I/O mapping and implemented a phased migration strategy to ensure seamless integration of the new system with minimal disruption to refinery operations.
- Installation of New Panels & SCADA Server: Installed state-of-the-art control panels and a robust SCADA server to support real-time monitoring and control of refinery processes.
- Site Acceptance Testing (SAT): Conducted rigorous SAT procedures to validate system functionality and interoperability.
- Operator Training: Provided hands-on training for refinery operators to ensure smooth adoption of the new system and maximize productivity.
- Zero Downtime Execution: Designed and executed the retrofit in a manner that ensured uninterrupted refinery operations throughout the project lifecycle.
The project was completed with meticulous attention to detail, adhering to international standards and achieving full compliance with Takreer’s operational requirements.
Key Features of the Project
Phased Migration Strategy
- Developed a phased migration plan to replace legacy components incrementally, minimizing risks and ensuring continuous refinery operations.
- Conducted parallel testing of old and new systems during the transition phase to verify data accuracy and system performance.
Advanced Control Infrastructure
- Upgraded the control system to Allen-Bradley PLCs, offering superior processing power, expandability, and cybersecurity features.
- Deployed Wonderware SCADA software to provide intuitive visualization, real-time analytics, and centralized control capabilities.
Precision I/O Mapping
- Conducted detailed I/O mapping to ensure accurate data transfer between field devices and the new PLC/SCADA system.
- Verified mappings through rigorous testing to eliminate errors and ensure optimal performance.
Robust SCADA Server Installation
- Installed a high-performance SCADA server with redundant configurations to ensure fail-safe operation and minimal downtime.
- Integrated the SCADA system with existing refinery networks, enabling seamless communication across all operational levels.
Comprehensive Operator Training
- Conducted hands-on training sessions for refinery operators, covering system navigation, troubleshooting, and advanced functionalities.
- Provided detailed user manuals and quick-reference guides to support ongoing system utilization.
Challenge 1: Ensuring Zero Downtime During Migration
Replacing a legacy system without disrupting refinery operations posed significant logistical and technical challenges.
Solution:
We implemented a phased migration strategy, replacing components incrementally while maintaining parallel operation of old and new systems. This approach allowed us to validate each phase before proceeding, ensuring zero downtime throughout the project.
Challenge 2: Accurate I/O Mapping
Migrating thousands of I/O points from the legacy system to the new PLC/SCADA platform required meticulous planning to avoid errors.
Solution:
Our team conducted detailed I/O mapping using specialized tools and verified mappings through rigorous testing. We also created cross-reference documentation to ensure traceability and accuracy.
Challenge 3: Operator Adaptation to New System
Transitioning to a modern SCADA interface required operators to adapt quickly to new workflows and functionalities.
Solution:
We provided comprehensive training programs, including hands-on workshops and simulation exercises, to familiarize operators with the new system. Post-training support was also offered to address any ongoing queries or concerns.
Challenge 4: Legacy System Integration
Integrating the new PLC/SCADA system with existing refinery infrastructure required careful coordination to avoid compatibility issues.
Solution:
We conducted thorough compatibility assessments and implemented middleware solutions where necessary to bridge gaps between old and new systems. Extensive SAT procedures ensured seamless integration and functionality.
Outcome & Client Satisfaction
The successful completion of the Onshore Refinery – PLC & SCADA Retrofit project highlights Lemos International’s ability to deliver complex automation upgrades under challenging conditions. Key achievements include:
- Seamless Migration: The phased migration strategy ensured zero downtime, allowing the refinery to maintain uninterrupted operations throughout the project.
- Enhanced Operational Efficiency: The upgraded PLC/SCADA system delivered superior performance, enabling real-time monitoring, predictive maintenance, and improved decision-making.
- Extended Scope Awarded: Our exceptional performance earned us additional scope from Takreer Refining Company, reflecting their trust in our capabilities.
- Operator Confidence: Comprehensive training programs ensured smooth adoption of the new system, empowering operators to maximize productivity.
Takreer Refining Company expressed immense satisfaction with the outcome, praising our technical expertise, proactive approach, and ability to deliver under tight constraints.
Why Choose Lemos International?
At Lemos International, we specialize in delivering world-class automation and control solutions for refineries, petrochemical plants, and industrial facilities. Our core strengths include:
- Proven Expertise in Automation Retrofits: With decades of experience in PLC and SCADA upgrades, we possess the knowledge and skills to tackle even the most complex projects.
- Commitment to Safety: Safety is our top priority, and we adhere to the highest HSE standards to protect workers and assets during execution.
- Focus on Quality: Our rigorous QA/QC processes ensure that every task meets or exceeds industry benchmarks, delivering reliable and long-lasting systems.
- Proven Track Record: Our portfolio includes numerous automation retrofit projects completed on time, within budget, and to the highest quality standards.
