Automation INSIGHT! December 2013 by DMS Global

Automation INSIGHT!

ISA Automation Conference 2013

Europe - Middle East - Africa insight! analytic

Weekly Market Analysis December 2013

insight! FEATURE

Interview with Ahmad Al-Khowaiter

featured project

YASREF - Yanbu Export Refinery Offsite Pipelines (Package 5)

Insight! Paparazzi

MEPEC - Bahrain

FIRST WORD Dear DMS Members,

COVER: Ahmad Al-Khowaiter Automation Insight! December 2013 Special Issue PUBLISHED BY Data Media Systems (for private distribution) PRINTED BY Oriental Press Manama, Kingdom of Bahrain President & CEO Mohammed Loch mloch@dmsglobal.net Administration Manager Sara Loch sloch@dmsglobal.net Editor-in-Chief Hugh Wingrove Editoral Designer Tracy Gutierrez tgutierrez@dmsglobal.net

Partner in achieving higher plant performance? Absolutely.

ABB offers you service and support that will enhance your project from the first concept to commissioning. We as your strategic partner contribute to lasting improvements across your project’s life cycle by bringing special expertise to the integrated engineering team, including multi-disciplinary experience and in-depth product and system integration knowledge. We operate locally while drawing support from our vast ABB resources around the globe. Our integrated solutions offer the industry’s best availability, quality, risk reduction and information flow. www.abb.com/oilandgas

For any suggestions and questions about AUTOMATION INSIGHT! please write to: insight@dmsglobal.net

Contents: 3 4-9 12-13 20-29

First Word Analytic Reports Company News Insight Feature Interview with Ahmad Al Khowaiti Interview with Hussain Qhatani 30-31 Paparazzi MEPEC - Bahrain 32-35 Industrial Automation and Control 36-39 Control System cyber Security 40-53 Wireless & Industrial Communications 54-66 Functional Safety and SIS 67-73 Asset Performance and Productivity Enhancements 74-79 Custody Measurement 80-87 Advanced Applications 88-91 Technology and Implementation 92-97 Installation, Operation and Maintenance Issues 98-101 Ex Standards 104-106 Featured Project YASREF - Yanbu Export Refinery - Offsite Pipelines (Package 5) 107-113 Project Listing

It give me great pleasure to present to the industry the first publication that truly addresses the technical issues of the Automation Sector for the Middle East. There are too many magazines in the region that are generic and thus have no real focus. In launching Automation INSIGHT! we have created a platform between the vendors, engineers and end users to communicate and share the latest automation technologies in the market. It is fitting that this pioneering publication is launched alongside the ISA Europe, Middle East, Africa Automation Conference and Exhibition 2013 as this event is also unique in it’s nature as the only real gathering point for the automation sector for technical exchange. Enjoy the first issue and we look forward to your comments for future issues as we develop this magazine with all of you to act as the voice for the industry. Mo Loch President and CEO DMS Global

Dear DMS Members, I was excited to be asked to become the Editorin-Chief for the Automation INSIGHT! magazine not least because, as someone who is naturally shy but also always likes to have the last word, it gives me the chance to finally have the 1st words in what I see as an important addition to the media available to us in this industry. We are very much in a project-based sales environment that relies on databases such as that offered by DMS to source information that will help us gain an advantage and, with the realisation that the automation group have very different requirements from others in the same industry, we now have a media tool that is focussed on our needs. Let’s all help to make this THE magazine in the automation industry by using is as the forum for asking and answering questions and providing good information and feedback to help us get what we want out of it at whatever capacity we are involved in within the industry. It will be released to coincide with the ISA Automation event in Saudi this year and that’s no coincidence since the 2 are interrelated with DMS’s involvement in organising the event and thus showing that they are committed to this industry. It’s exciting to be involved in both. Thank you DMS! Hugh Wingrove Editor-in-Chief DMS Global december 2013 | Automation INSIGHT! | 3

Ras Tanura is the oldest refinery on the Persian Gulf coast, located near the industrial port city of Jubail, Saudi Arabia. It has a crude distillation capacity of 550,000 barrels per day (bpd) and it is owned and operated by the state-owned oil company, Saudi Aramco. Majority of the products produced by the refinery are supplied to Dhahran bulk plant for domestic use, while the remaining is exported. The refinery began operations in September 1945 with an initial production capacity of over 60,000 bpd. It has since then undergone a number of expansions, which added new equipment such as fluid hydro former for highoctane gasoline production (commissioned in 1955), a diesel de-sulphurization unit (commissioned in 1957), a special products blending facility, and a refrigerated liquefied petroleum gas (LPG) plant.

CMYK

Telinstra is a specialist Consulting and Systems Integration company providing critical solutions and advisory services to some of the Middle East region’s most important clients in the Oil & Gas, Utilities, Transport Infrastructure and Manufacturing sectors.

Solutions

 



  



Services

Process Instrumentation Advanced Control & Automation Safety Systems (ESD, F&G, HIPPS) Pipeline Leak Detection System Switchgear & Motor Control Centers Power System Study Centralised Control Rooms Real-time Business Intelligence Asset Management IT Services Enterprise Mobility Solutions Enterprise Risk Management Change & Communications Master Data Management (MDM)

Consultancy  Knowledge Management & Sustainability  Conceptualization  Process Improvement & Optimization  Automation System Audits Engineering & Implementation  System design  Electrical Engineering & design  Functional design  Software development  Assembly & Manufacturing  Testing  On Site installation & Commissioning  System Integration  Project & Programme Management Training  Systems & application  Product Support Services  Onsite services  On-call services  Remote & virtual services  Spares management

w w w.t e l i n s t ra . c o m

The most complex Saudi Aramco refinery, Ras Tanura processes both crude oil & gas condensates. It is part of a very large scale complex, with a NGL processing facility and a crude stabilization facility. The project is part of Aramco’s plans to upgrade its domestic refining capacity to both lower the sulphur content of its downstream output and diversify the amount of refined products it produces. The specific aim of the Ras Tanura refinery expansion is to supply middle distillates such as diesel and kerosene to help meet the country’s rapidly growing domestic fuel consumption needs. On 13 October 2013, Japanese contractor JGC Corporation emerged as the solitary bidder for the offsites and utilities package at the $3 billion refinery’s clean fuels and aromatics scheme. The Japanese contractor was the only engineering, procurement and construction (EPC) contractor to offer a submission to Aramco and it is now expected to enter into a direct negotiation with the state-owned oil major. The original scope of the project amounted to about 400,000 man-hours in total. However, since Jacobs Engineering carried out the front-end engineering and design (feed), this figure has since risen considerably. Currently, the scope of works will include carrying out feed services for the inside and outside battery limits,

The major facilities at the refinery complex include a 325,000 bpd crude distillation unit, a 225,000 bpd gas condensate distillation unit and a 50,000 bpd hydrocracker. In addition, it has 270,000 bpd catalytic reforming equipment. It also includes a vis-breaker and a natural gas liquids (NGL) industrial unit. The NGL fractionation plant was added with a capacity of

130,000bpd in 1978. A modernization project was completed at the refinery in 1984 while the refinery was also upgraded by adding diglycol amine (DGA) regeneration plant and sour water stripper in 1999. At present, there are only two more packages remaining on the Ras Tanura rehabilitation and expansion scheme. They are: • Naphtha and aromatics processing facilities • Paraxylene production facilities Contract awards for these packages are expected in the first quarter of 2014 and the construction phase is set to last 42 months. Commissioning of the entire refinery is slated for mid-2017.

UAE Plans to Develop an Independent Islamic Finance Authority The United Arab Emirates plans to develop an independent authority which will supervise the country’s Islamic finance industry, backed by specific legislations. A centralized approach to supervising Islamic finance is increasingly being adopted around the globe, as regulators try to standardize industry practices and improve consumer perceptions. A sharia authority has also come onboard, that will be outside the central bank. Lately, Dubai has shown huge aspirations to become the global capital for sharia-compliant business. Dubai’s selection at the end of October as host of next year’s World Islamic Economic Forum marks an important step towards fulfilling its ambition of becoming the capital of the global Islamic economy.

Islamic finance, with its current Islamic finance assets totaling $118 billion. With their new plans, the growth of Islamic finance is expected to accelerate in the coming years and help to create a safe investment haven in the region.

World Leading Experience in Flow Control

The Islamic market is quite uneven, suffering from a lack of standardization and confusing legal frameworks, while cooperation between the various sectors remains rare. However, UAE and Dubai, in particular, is intent on changing that. Recognizing the growing popularity of sharia-compliant and so-called Muslim-friendly products, UAE plans to tap into the region’s expansive Arab market and lead the way for Islamic business across the globe. Dubai’s ruler Sheikh Mohammed bin Rashid Al Maktoum has also outlined plans to focus on seven Islamic pillars over the next three years. Through the development of Islamic finance, halal food, tourism, the digital economy, arts and design, standards and certification, and education, the aim is to create a cohesive, globally significant framework for the Islamic economy.

Stand number H16

JGC Corporation Sole Bidder on Saudi Aramco’s $3 billion Ras Tanura Refinery

as well as modifications to the refinery to ensure it meets environmental regulations. An aromatics cracker has also been added, which will allow for a far-greater diversity of products being manufactured at the plant.

See us at ISA Automation Conference & Expo EMEA 2013

Analytic Report

analytic

Rotork is the global market leader in valve automation and flow control. Our products and services are helping organisations around the world to improve efficiency, extend reliability and protect the environment. Rotork Middle East FzeR8 OA LC07, Jebel Ali Free Zone, PO Box 262903, United Arab Emirates 262903 tel fax

+971 04 887 6408 +971 04 887 6409

The UAE is already the fourth-largest centre for december 2013 | Automation INSIGHT! | 5

analytic

The new legislation which is being developed by the UAE government would enhance the authority’s ability to influence industry practices as they would develop a set of standards, not just in finance but also in other areas such as halal food processing, which would become accepted internationally.

Furthermore, the Islamic Development Bank (IDB) has planned a $10 billion rolling programme of sukuk issues that will be a major boost for Dubai’s ambitions to be a global hub of the Islamic economy.

Impact of Shale Gas Likely to Affect GCC Countries in the Long Term The discovery of shale gas should be a wake-up call for producers of GCC petrochemicals as the Gulf must rationalize and improve efficiency to face stronger competition from the US and Asia. Analysts feel that the GCC’s oil and gas producers need to have innovative strategic plans as competition intensifies. The effects of shale oil and gas production in North America could impact oil prices in the medium to long term Saudi Arabia’s Deputy Minister of Petroleum & Minerals Prince Abdul Aziz bin Salman Al-Saud warned that Gulf petrochemicals producers will face an era of stronger competition after the region’s rise as a major chemicals exporter.

“In the next decade, the GCC will face stiffer competition from new players with more energy efficient plans, more availability of gas, greater access to technology and higher capacity to innovate,” said Prince Abdulaziz, speaking at the Gulf Petrochemicals & Chemicals Association (GPCA) Forum in Dubai on 20 November. “The US’ rapid growth in shale gas has brought a sharp growth in the availability of ethane and propane leading to what some have described as renaissance of petrochemicals manufacturing,” he said. “Governments in Asia are also keen to develop their growth in petrochemicals to keep up with rising demand. This environment of increased global competition should be a wake-up call for all the GCC petrochemicals industry to rationalize and improve efficiency,” he added. However, analysts also predict that the negative impact of shale gas on the GCC won’t be significant for at least another 20 years, citing the high cost of shale gas and projected growth in Asia’s oil consumption. In fact, Asia’s oil consumption growth, which is driven by fossilfuel hungry economies, is expected to outpace natural gas consumption during the same period. Therefore, the Gulf is successfully shifting their attention to cater to that demand.

from being the world’s leading importer of oil to a net exporter by 2017, and become energy independent by 2030, the lost demand for oil from the US will be offset by Asia.

Kuwait Plans $75 billion Spending on Infrastructure Projects Kuwait is planning a $75 billion infrastructure spending on energy, power and housing projects until 2016, a move that is raising optimism about the projects market in the country and the economy in general. National giants Kuwait Oil Company (KOC), in line with their expansion plans, have themselves decided to invest $1.3 billion on building power substations and associated infrastructure across the country. Industry sources within KOC have revealed that the capital expenditure of $45.9 billion between 2014 and 2019 would ensure that the oil company’s ambitious expansion plans would have the necessary power and electricity infrastructure.

transform the country’s investment environment and encourage foreign investment has been passed. This will further push the projects market forward. Therefore, over the next five years, the oil and gas sector in Kuwait will be the main beneficiary of a hopefully more realistic and intensive approach to key investments. Conversely, the renewed optimism is rubbing off on other sectors as well such as the planned investments in the healthcare sector, valued at $3 billion, over the next five years.

Recently, KOC has also issued a long-awaited tender for the $4.2 billion Lower Fars heavy oil development. By 2020, KOC is planning to have increased oil production rate from the current 3 million barrels per day (bpd) to 3.65 million bpd. Furthermore, commercial proposals are expected to be received shortly for the three packages that make up the $17 billion Clean Fuels Project (CFP), a scheme that involves a major revamp of Kuwait’s three existing refineries to improve their efficiency and meet higher international fuel standards.

On the other hand, prices will probably be affected, reducing oil revenues in the GCC and making Asia more competitive due to cheaper inputs. As a result, GCC’s leading global position as an energy exporter will be sustained despite advancements made in fracking technologies.

Signalling a turn of fortune for Kuwait’s energy sector, Kuwait National Petroleum Company (KNPC) has also awarded the project management consultancy contract for the $14 billion New Refinery Project. Once completed, these projects will have a significant impact on the country’s economy.

Moreover, switching to natural gas doesn’t come cheap as there are high costs for importers to bear when they switch from conventional oil to natural gas. Another factor is the time required to establish a more stringent regulatory framework for shale energy to adhere to environmental concerns. And most importantly, Asian demand is rising for conventional oil, which will prevent the world’s energy landscape from rapidly changing. In fact, the EIA expects China to rely massively on coal and oil to cover around 80 per cent of its energy needs in the next two decades.

Bids are also expected in late January 2014 for one of the largest upstream projects in the region. The single engineering, procurement and construction (EPC) tender includes five main parts covering a steam injection facility, production facilities, a support complex, tank farms and a 270,000 barrel per day (bpd) pipeline to transport the heavy crude to the planned new refinery in the south of Kuwait. Although its production target is relatively modest, the fact that it is planned as a single EPC project sets it apart.

OPEC projects that China’s imports of crude oil will 6 | Automation INSIGHT! | decEMBER 2013

outpace the US crude oil imports by 2014, as its rising refining capacity is propping up demand. The rest of Asia will also play an important role in keeping oil demand high. Furthermore, even if the US is able to tap its reserves adequately, and would shift

Lately, Kuwait has also had favorable changes in its political landscape as a new legislation designed to

Analyycal Instrumentaaon & Maintenance Systems (AIMS) Specialist in Analyzer's Integraaon & Service Provider AIMS is leading Instrumentaaon company in GCC having its based in Abu Dhabi, UAE and regional offices in Saudi Arabia, Qatar, Kuwait. AIMS have a state of art workshop for mull-faciliies like Integraaon, In-House project facility, Tessng, FAT, Installaaon, Calibraaon, Training. AIMS emerg emerged and retained its core competency in Analyzer services and have been involved in Analyzer maintenance, Installaaons, Commissioning, Up-gradaaons, Annual Maintenance for major Oil and Gas Customer in GCC. More than 50 engineers are working in different site to saasfy customers and resolve problems. For peace of mind, avoiding added cost, and inconvenience of emergency situaaons!!! situ AIMS invite you to bring up and discuss your challenges and experience with Analyzer System and assure you to be part of your team in resolving it for forever… Please feel free to contact us AIMS PO Box 34915, Abu Dhabi, UAE Tel: +971 2 6436114 Fax: +971 2 6436115

december 2013 | Automation INSIGHT! | 7 info@aimsgt.com www.aimsgt.com

analytic

Dubai Set to Wow the World with Expo 2020 The United Arab Emirates (UAE), and Dubai in particular, is expected to push itself to the next level in the run up to the World Expo trade convention in 2020 as they look to open arms to more than 25 million visitors into the city. The expo enables hundreds of countries show off the latest in architecture and technology. With its theme “Connecting Minds, Creating the Future”, innovation will be one of the cornerstones of the Dubai Expo. A World Expo in Dubai in 2020 would also be the first to be held in the MENASA (Middle East, North Africa and South Asia) region. Victory for Dubai, which is home to the world’s tallest tower, largest man-made island and one of the world’s busiest airports, means the World Expo 2020 will be hosted by an Arab country for the first time. The site chosen for the event is spread over 438 hectares (1,082 acres) and located between the international airports of Dubai and Abu Dhabi, the capital of the Emirates. Dubai has a long history of facilitating connections and pioneering new ideas and Dubai Expo 2020 would be no different, with a predicted 70 per cent of the expected 25 million visitors originating from outside the host nation, making it the most international event in the history of the Expo. The focus will be on exploring their inter-dependencies and identifying potential partnerships, ultimately resulting in a legacy of innovation. As the global community faces ever more complex and increasingly interconnected challenges, the links between people, societies and

ideas have never been more important. Hence, Dubai Expo 2020 will be a platform for connectivity to help pioneer new partnerships for growth and sustainability for the future. Observers claimed that Dubai Expo 2020 is undoubtedly expected to stand out as the best edition in the history of the event in terms of preparation and presentation. Moreover, Dubai is also the economic and transport hub of the United Arab Emirates. It would therefore provide a unique platform for the global community to come together and explore creative and pioneering solutions to the three sub-themes which have been identified as key drivers of global development: • Sustainability: lasting sources of energy and water • Mobility: smart systems of logistics and transportation • Opportunity: new paths to economic development Already known for its world-class infrastructure, Dubai will further invest in its roads, public transport and airports, making the city even easier to get around. Furthermore, the investments leading up to the Expo 2020 will go well beyond pure hard infrastructure, with further additions in areas such as education, healthcare and culture to be anticipated. Analysts say that the vibe and the excitement of Expo 2020 gives an additional boost of positive energy to this already buoyant city and nation. It also brings yet another major common goal for all communities to rally around, contribute to and feel proud of within Dubai and the UAE in general. The Expo 2020 is also expected to create over 250,000 jobs, especially in sectors such as construction, hospitality and aviation. By itself, this represents a sizeable economic impact. In short, Dubai Expo 2020 will breathe new life into the ancient role of the Middle East as a melting pot for cultures and creativity.

UAE Oil and Gas Expenditure Governs GCC In 2013 The UAE has dominated the GCC oil and gas projects market in 2013, awarding a higher value of contracts than all the other GCC members combined. In fact, the city of Abu Dhabi projects a market much higher than the other five Gulf States combined in first ten months. In the first ten months of the year, $18.4 billion in engineering, procurement and construction (EPC) contracts was awarded on oil, gas and petrochemicals projects in all the GCC countries compared with $26.3 billion for the whole of 2012. Out of these, approximately $11 billion was awarded in the UAE as Abu Dhabi stepped up spending on major 8 | Automation INSIGHT! | decEMBER 2013

developments at its offshore oil and gas fields. Abu Dhabi has now begun the bulk of the construction work on its plan to expand production at the Upper Zakum, Satah Al Razboot (Sarb) and Umm al-Lulu fields with further awards expected on the Nasr field in 2014. Traditionally, Saudi Arabia had been the highest spender over the last couple of years. In 2011, they spent $17.2 billion, while in 2012 they exceeded that figure with an outlay of $19.4 billion. However, the kingdom has spent just $4.2 billion so far in 2013. This fall in awards has helped the UAE spending for 2013. However, Saudi Arabia is expected to recover in 2014 with $8.8 billion worth of oil

and gas contracts to be distributed. Other GCC countries like Kuwait and Qatar have only spent $1 billion and $1.4 billion respectively on oil and gas projects during the first ten months of 2013. Qatar’s only large award was a $1.2 billion deal on phase two of its Laffan condensate refinery, while Kuwaiti contracts included liquefied natural gas (LNG) facilities and drilling at the Lower Fars field. Oman’s awards totaled just $835 million including the development of the Block 65 onshore oil concession

and gas facilities at the Yibal field. Expenditures in Bahrain were also peripheral with a solitary $17 million contract awarded. In 2014, the UAE is still expected to stay top of the spending chart if contracts are awarded for the Fujairah refinery and the new petrochemicals complex planned in Ruwais.

Bids Submitted for Mina Al Ahmadi (MAA) and Mina Abdullah (MAB) Refineries National giants Kuwait National Petroleum Company (KNPC) owns and operates two refinery complexes, namely the Mina Al Ahmadi (MAA) and Mina Abdullah (MAB) Refineries. They are meant to produce gasoline with no more than 10 ppm sulfur, compared with 500 ppm now. KNPC has decided to upgrade and expand the MAA and MAB refineries as part of their plans to integrate both the projects into one major refining complex. Estimated to be around $17 billion, the Clean Fuel project will consist of three phases. Foster Wheeler, along with its subsidiary Global Engineering and Construction Group is providing project management consultancy (PMC) services contract on both the refineries. In November 2013, several pre-qualified companies submitted bids for the engineering, procurement and construction (EPC) contract. It is likely to be awarded in the first quarter of 2014. The main objective of clean fuel package is to: • Meet year 2020 market demands and specifications for transport fuels • Increase processing capacity at MAA/MAB to 800000 BPSD from 736000 BPSD (after SHU Retirement). • Integrate operating capability of the MAA/MAB with optimum utilization of the existing Infrastructure. However, this means benzene and aromatics concentrations also will decline. The CFP will lower gas oil sulfur content to as low as 10 ppm, depending on destination. The facilities now produce gas oil with 500-5,000 ppm sulfur. Bunker fuel oil sulfur content will also drop from the current 4.5 ppm to 1 ppm., while the maximum sulfur content of full-range naphtha will drop from 700 ppm to 500 ppm. Mina Abdullah Refinery (MAB) became a state property, following a transition period in 1978 during which the refinery was managed

by a national company under the name of “Wafra Oil Company”. It was then transferred to KNPC. The refinery was first built in 1958 during the rule of the late Sheik Abdullah Al-Salem Al-Sabah, by the American Independent Oil Company “AMINOIL”. It was at that time a simple refinery that contained one crude oil distillation unit with a capacity of approximately 30,000 bpd. Following several expansion projects between 1962 to 1967, its refining capacity rose to approximately 145,000 bpd. The total area covered by its installations is 7,935,000 square metres. Analysts have also said that the clean fuels project will re-shape the refining industry in Kuwait as the packages will re-configure the country’s three refineries and, in conjunction with grassroots construction planned at Al Zour, nearly double total refining capacity to 1.4 million bpd. The project will also enhance and make sure a reliable power supply is available to help Kuwait meet its future market demand for transport fuels by 2020, as it seeks to increase processing capacity at its refineries. december 2013 | Automation INSIGHT! | 9

We Give Your Creativity

Infinite Possibilities

xxxxx xxxxx xxxxxx xxxxx xxxxxxxxxxx xxxxxx xxxxxx xxxxxxxxxxxx xxxxxx xxxxxxx xxxxx xxxxxx xxxxxxxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxx xxxxxxxxxxx xxxxxxx xxxxxx xxxxxxxxxxxx xxxxxx xxxxxx xxxxxxx xxxxxxxxxxxx xxxxxxxxxxxxxx xxxxxx xxxxx xxxxxxxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxx xxxxxx xxxxxxxxxxx xxxxxxx xxxxxx xxxxxxx xxxxxxxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxx xxxxxxxxxxxxxx xxxxxx xxxxx xxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxx xxxxxx xxxxxxxxxxx xxxxxxx xxxxxx xxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxx xxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xx xxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxx xxxxxx xxxxxxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxx xxxxxx xx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxx xxxxxx xxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxxx xxxxxx xxxxx xxxxxx xxxxxxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxx xxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxx xxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxx xxxxxx xxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxx xx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxx xxxxxxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xx xxxxxx xxxxxx xxxxxxxxxxxx xxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxx xx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxx xxxxxxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xxxxxxx xxxxxxxxxxxx xxxxxxxxxxxxxx xxxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxx xxxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxxxxxxxxxx xxxxxx xxxxxxxxxxx xxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xxxxxxx xxxxxxxxxxxxxx xxxxxxxxxxxx xxxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxx xxxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxx xxxxxx xxxxx xxxxxxxxxxxxxx xxxxxx xxxxxxxxxxx xxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxx xxxxxx xxxxxx xxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxxxxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxx xxxxxxxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxxxxxxxxxx xxxxxx xxxxxxxxxxx xxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xxxxxxx xxxxxxxxxxxxxx xxxxxxx xxxxxxxxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xx xxxxxx xxxxxxxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxx xxxxxxxxxxxxxx xxxxxx xxxxxxxxxxx xxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxxx xxxxxx xxxxxxx xxxxxx xx xxxxxxx xxxxxx xxxxxxx xxxxxxx xxxxxx xxxxx xxxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxx xx xxxxxx xxxxxxx xxxxxxx xxxxxx xxxxxxxxxxxxxx xxxxxx xxxxxxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxx xxxxxx xx xxxxxxxxxxxx xxxxxxx xxxxxx xxxxxxx xxxxxxx xxxxxxxxxxxx xx xxxxxxxxxxxxxxxxxxxxx xxxxxx xxxxxx xxxxxxx xx xxxxxx xxxxxxx xxxxxxxxxxxx xxxxxx xxxxxxxxxxxxxx xxxxxx xxxxxxx xxxxxxx xx xxxxxx xxxxxx xxxxxx xxxxxxx xxxxxxx xx xxxxxxx xxxxxx xxxxxx xx xxxxxxx xxxxxxx xxxxxx xxxx

ASSIGN

1 R

NO FILTE

AUTO

MAN

2 INFINIT

1 PUSH

DER

DIGITA

L HD

VIDEO

CAME

RECOR

FX1 HDR-

AUTO LOCK

GAIN

Photography

Audio Production

Film and Video Production

With our main headquarters in the Kingdom of Bahrain, DMS CyberNation is an awardwinning media production house, offering a comprehensive range of products and services. Over the years, we have amassed an international pool of complementary, creative and technical abilities, which has enabled us to provide a full range of the highest calibre of film, audio, digital and photography production services. DMS CyberNation’s mantra: it is not acceptable to compromise on quality and creative integrity. DMS CyberNation now consistently provides internationally acclaimed TV Commercials, Corporate Films, and Digital Media to a vast and diverse clientele; from individuals to advertising agencies and corporations.

Digital Solutions and Web Development

By design, DMS CyberNation is a ’boutique’ style company, which allows flexibility, personalized service, and the ability to keep budgets low. It does not matter how well story boards and production schedules are planned, there are invariably last minute changes, and we are geared up to adapt to these changes with minimal adjustment to creative integrity and budgets. Over the years, we have formed beneficial collaborations with top professionals and companies, which has allowed us to guarantee the best and the latest. We still believe that people are our greatest resource, and today DMS CyberNation boasts a dynamic core team of 25 professionals from around the world. Our commitment to invest in our people and technology allows us to consistently produce work that lives up to the high standards associated with our name.

Get started on your project today. Contact Us now for a free assessment. CONTACT US

Tel: +973 1740 5590 • Fax: +973 1740 5591 • info@dmsglobal.net www.dmscybernation.net

Company news

Company News

Discover Metso’s unique service and solution offering for the oil & gas industry at ISA Automation Conference 2013 in Dammam, Saudi Arabia Authors: Aija Kalander and Juha kivela During the ISA Automation Conference, Metso’s experts will present the following papers: • Finding the Business Value of Basic Control Performance, by George Buckbee on Tuesday the 10th of December at 2:30 pm in Room 3 • Fugitive emission certified valves enhance process plants’ safety, by Ville Kähkönen on Thursday the 12th of December at 10:00 am in Room 2 At Metso stand, the company will showcase its latest innovations, beginning with an extended capability version of the famous Q-Trim™ noise reduction technology and Metso Valve Manager™, representing state-of-the-art 3rd generation valve

There is more to Metso than meets the eye.

diagnostics. In addition, Neles ValvGuard VG9000, the latest version of Metso’s well-known intelligent safety solenoid with partial stroke testing capability, will be available for a comprehensive demonstration at the stand.

environment. The underlying root cause of these losses is the failed performance of the mundane control loop. Metso will present a paper at the conference and also host an in-depth training workshop on Control Loop Performance Monitoring and Tuning on Monday the 9th of December during the training part of the ISA Automation conference. The four-hour Control Performance workshop starts with an overview on the basics of control performance and progresses through to more advanced topics. Attendees will learn the basics of loop tuning, and instrument and valve troubleshooting. The later part of the session emphasizes more complex issues, such as oscillation and interaction analysis to find the root cause of process upsets.

Fugitive emission certified valves enhance process plants’ safety, Thursday 12th of December

Metso’s experts will available to discuss oil & gas industry topics and challenges at ISA Automation Conference, 10th to 12th of December 2013 in Dammam, Saudi Arabia. In-depth training workshop on Control Performance, Monday 9th of December

End users are encouraged to require the most comprehensive valve emission testing standard at the moment from their valve suppliers, represented by ISO15848-1. This provides significant health, safety and environmental benefits for process plants.

The process industry is losing trillions of dollars because of underperforming control systems. These losses are measured in the form of lost production, energy, materials, safety, quality, and the

All process valve related FE standards aim at the same objective: to comply with the applicable local fugitive emission legislation and to reduce fugitive emissions from the valves to prevent environmental damages. This takes expertise to understand the different requirements of the FE standards. A direct comparison of the various fugitive emission standards is not that straightforward. The fugitive emission standards are a relatively strict standard for valves based on the analysis of FE standards and extensive laboratory based research knowledge. That information can be transferred into valuable end-user benefits.

Look what goes into a Metso valve. It starts with a long track record of delivering engineered performance and legendary reliability with premier products such as Neles®, Jamesbury® and Mapag®. But the numbers really paint the picture. In almost 90 years, Metso has delivered globally millions of valves, control valves and onoff valves. We have also become one of the leading suppliers of smart positioners. All backed by field service expertise from over 55 automation service hubs and over 30 valve service centers around the world. We see it this way: keeping oil and gas producers working safely and reliably protects investments, people and the planet. Discover more at www.metso.com/oilandgas/flowcontrol Neles® • Jamesbury® • Mapag®

Growing presence in the Middle East, new service centers to be established Metso Automation’s Middle East Operations are headquartered in Dubai. To fulfill our objective of being closer to customers, Metso offers locally comprehensive capabilities in application engineering, project management, smart technology and after-market and plant performance services. Therefore, Metso is constantly growing its presence in the Middle East, especially in Saudi Arabia, Qatar, United Arab Emirates and Kuwait. Besides the major markets, Metso is well represented in the other countries in the region as well, including Pakistan, Oman, Bahrain, Jordan, Yemen and Iraq. In 2014 Metso will be opening a new service center in Qatar to further support end users in Qatar and in neighboring countries. The service center in Qatar will be followed by similar developments in Saudi Arabia and the UAE.

Experienced in valves Metso’s state-of-the-art solution portfolio is designed to improve safety and productivity in the oil & gas industries. Metso’s target is to

12 | Automation INSIGHT! | decEMBER 2013

maximize production efficiency and reduce safety risks throughout the life cycle of a plant, starting from simplifying valve selection, improving process availability and maximizing production performance. Metso has a long track record of delivering engineered performance and reliability to the oil & gas industry with its leading brands Neles®, Jamesbury® and Mapag®. In nearly 90 years, Metso has delivered globally millions of valves, control valves and on-off valves, and has become one of the leading suppliers of intelligent valve controllers. All of this is backed by field service expertise from currently over 55 Metso Automation service hubs and over 30 valve service centers around the world. Automation’s valve technology and supply centers are located in Finland, the US, Germany, China, South Korea, India and Brazil. The Automation segment’s process automation and flow control solutions meet the growing needs of Metso’s customer industries to improve production process efficiency as raw materials and energy sources become scarcer and their costs increase. Our global network of service experts delivers business solutions to our customers that improve their productivity, lower risks and optimize costs. www.metso.com/automation, com/metsoautomation

www.twitter.

Metso is a global supplier of technology and services to customers in the process industries, including mining, construction, pulp and paper, power, and oil and gas. Our 30,000 professionals based in over 50 countries deliver sustainability and profitability to customers worldwide. Expect results. www.metso.com, www.twitter.com/metsogroup For more information: Juha Kivelä, Business Development Manager, Technology, Middle East Mobile: +974 5582 0548 juha.kivela(at)metso.com Lindsay Coutinho, Country Manager,- Middle East- Region 2 Mobile: +973 3969 8619 lindsay.coutinho(at)metso.com december 2013 | Automation INSIGHT! | 13

Company news

Company News

Cameron – Valves & Measurement Cameron brings together the expertise and technology of the world’s premier brands into one single, industry-leading entity. Cameron’s Valves & Measurement business segment is a leading provider of valves, measurement and valve automation systems to the global energy and industrial markets. Discover the products, the people and the services that deliver optimum value for all your valve needs. Discover Cameron’s valves. Across oil and gas disciplines, around the world, we offer the industry’s broadest portfolio of valves, the unmatched experience of knowledgeable global valve experts, and a seamless process that integrates industry best practices with comprehensive support from pre-FEED to aftermarket. For leading oil and gas businesses, Cameron’s Measurement Systems division emerges from a legacy of constant innovation – offering a broad assembly of measurement solutions that continuously raise performance. We have a history of inspiring innovation and forming a bridge to expertise, with field-proven product brands,

a comprehensive portfolio and worldwide sales and service channels. Cameron is your strategic partner in raising the bar. Cameron’s valve automation portfolio includes power actuation and manual gear technologies that complement the operational excellence of Cameron’s manufactured valve brands, as well as third-party valve products. Engineered to deliver solutions across the entire industry, Cameron’s Valve Automation team offers a single, comprehensive 6D valve automation portfolio – for any valve, in any application. Built on years of engineering expertise and a history of valveneutral proven performance, Cameron’s valve automation brands deliver solutions with local support to the global valve market, all back by Cameron’s CAMSERVTM aftermarket services.

BS&B Safety Systems: Experts In Overpressure Relief and Explosion Protection Solutions Author: David Zengerly BS&B Safety Systems is a leading global producer of bursting disks, buckling pin devices and explosion protection solutions designed for industrial processes. Founded in 1931, the company’s innovative history spans more-thaneight decades with BS&B engineers responsible for developing much of the overpressure relief technology in use today. BS&B offers a comprehensive portfolio of products and services that meet and exceed rigorous industry standards for quality and reliability. Our integrated solutions have been time-tested and fine-tuned to deliver maximum value and greater efficiencies to individual engineering processes. BS&B offers a broad range of overpressure relief devices, which are fast, accurate and dependable. By offering a wide selection, BS&B can meet your specific needs. • Disk sizes ranging from 3mm to 1120mm • Pressures from mbar g to 6900 bar g 14 | Automation INSIGHT! | decEMBER 2013

• Custom engineered and designed bursting disks • Fast-acting and quick-reset, while installed, Buckling Pin Devices • Dust Explosion Management Solutions

BS&B Buckling Pin Devices BS&B produces fast acting/quick opening buckling pin devices (inline and angle) designed to protect personnel, equipment and environment from the dangers of overpressure. Buckling pin devices provide the accuracy of a rupture disk. However, because of because of the devices quick and easy field-reset and ability to remain installed during reset, plant downtime is dramatically reduced. Sizes range from 25mm to 1800mm for buckling pin relief valves. In fact our 1800mm BPRV, first released in 2007, was the world’s largest ASME certified pressure relief device in the world. Buckling Pin Angle Valve was the first API-526 piping configuration buckling pin valve. Its sizes are 25mm x 38mm to 205mm x 260mm.

BARTEC BENKE On-Line Process Analyzers Author: David Zengerly BARTEC BENKE on-line process analyzers for liquids continuously supply the relevant process parameters to allow optimum process management, ensuring that the quality produced comply with the applicable standards and product-related specifications. BARTEC BENKE offers a wide range of high-quality analyzers. One of them is the Distillation Process Analyzer: The redesigned BARTEC BENKE Distillation Process Analyzer (DPA-4) remains the benchmark for physical property analyzers. The DPA-4 is still the only ASTM D86 compliant analyzer available regarding both apparatus and procedure. Refinery operator requirements have had a significant influence on the redesign of the DPA-4. The result is the faster Rapid Analysis Method (RAM) beside the Standard Analysis Method (SAM) which is still fully compliant to the ASTM D86 laboratory method. Reduced analysis cycle time in both, SAM and RAM mode is achieved due to improved systems and components. Switching between the methods after any desired measurement cycle is programmable or manually selectable which allows maximum flexibility (e.g.: x RAM-cycles and occasional SAM-cycles for validation). The faster RAM also uses the measurement components required by the ASTM D86 method for a complete analysis, including a flask, condenser and receiver. However, due to the unique design, measurement cycles can be reduced by approx. 40%. The implemented de-coking program removes coking layers of the measurement components and therefore minimizes the maintenance requirements significantly. This also allows the use of samples which tend to coke. Advantages at a glance: • ASTM D86 compliance in Standard Analysis Method • Excellent accuracy with regard to repeatability and reproducibility for optimal process control • New Rapid Analysis Method allows for faster measurement cycles at any time • Reduced maintenance efforts • Lower height due to elimination of external components

Process Analyzer Solutions

UPSTREAM

MIDSTREAM

DOWNSTREAM

The World of Safe.t® Analyzers and Systems

Optimize your production efficiency to obtain high-quality products! BARTEC BENKE online-analyzers continuously provide measurements of    

BARTEC BENKE

Cloud Point Distillation Curve Freezing Point Vapor Pressure

   

Cold Filter Plugging Point Flash Point Pour Point Viscosity

according to applicable international standards.

Phone: +49 (40) 727 030 Benefit from the widest range of high-quality december 2013 | Automation INSIGHT! | 15 physical property analyzers accompanied by cooling pat@bartec-benke.de www.bartec-benke.com systems, auxiliary systems and suitable housing.

Company news

Company News

FLUXUS F808 - clamp-on flow meter for hazardous areas ATEX Zone 1, IECEx and FM Class I, Div. I approved Author: Oliver Foth With the FLUXUS F808, FLEXIM moves one step further and presents its first clamp-on flow meter for liquid measurement in hazardous areas with an ATEX Zone 1, IECEx and FM Class I, Division I approval. The highly rugged FLUXUS F808 flameproof housing is suited for every industrial application - not only offshore. With its connection and electronic compartment being hermetically sealed, the FLUXUS F808 provides for maximum operational safety and is especially designed for use in rough industrial environments such as chemical and petrochemical plants. In conjunction with the extremely robust transducers and the PERMAFIX transducer mounting fixture (Stainless Steel SS316), which

Non-intrusive Gas Flow Measurement for Gas Transport Gas Storage Gas Distribution

ensures a permanent contact pressure to the pipe wall and an extreme mechanical stability, the FLUXUS F808 is the most reliable ultrasonic clamp-on flow meter available. Since the ultrasonic transducers are mounted on the outside of the pipe, the system does not suffer from wear, tear, or clogging. Moreover, the system is not susceptible to pressure drops and leaks. Not only is the FLUXUS F808 rugged, it also offers an unmatched zero stability due to carefully matched and temperature compensated transducers (fully ANSI / ASME compliant). Highly innovative digital signal processing within the flow meter insures the most reliable, repeatable and accurate bidirectional flow measurement over a wide turndown ratio. The FLUXUS F808 flow meter can be applied at inner pipe diameters ranging from 1/4 inch up to 20 feet and more independent of pipe material, wall thickness and liquid viscosity. Even liquid streams with a high content of solids or gas bubbles are not a problem due to the innovative HybridTrek mode, and the unique signal processing implemented into the flow computer.

HIMA Middle East is Now FSM Certified Facility Author: Safyan Ali HIMA Middle East, a member of the worldwide HIMA is now Functional Safety Management (FSM) certified facility.

liability risk with documented safety standards.

The FSM Certification is a strategic building The objective of functional safety management is to identify the block for a long-term and lasting business management activities that are necessary to ensure the functional relationship, which brings success to the company Hima - Quarter Page.pdf 1 11/4/13 11:55 AM safety objectives are met. HIMA’s FSM system explains the company and boosts its image. principles, objectives and the measures for achieving the functional safety management. The system is aimed to identify persons, departments, organisations or other units which are responsible for carrying out and reviewing each of the safety life-cycle phases and informed of the responsibilities assigned to them (including where relevant, licensing authorities or safety regulatory bodies). HME activities involved in project execution phase i.e. design & engineering of safety instrumented systems (SIS) constitute Phase 4 of IEC 61511 Safety life cycle.

HIMA solutions provide maximum safety and process availabiliy

This prestigious certification is highly respected in the Middle East market as a serious supplier with the capability to ensure functional safety is achieved for every deliverable. Being a FMS certified facility; HIMA Middle East is committed to ensure compliance with domestic and international standards and to reduce

Clear Advantages:  Bidirectional Measurement  Installation under Process Conditions  No Risk of Leakage

   

No Wear and Tear No Pressure Drop ATEX-certified High Dynamic Range

16exim.co.uk | Automation INSIGHT! | decEMBER 2013 www.fl

+971 4 883 4489 +971 4 883 4778 december 2013 | Automation INSIGHT! | 17 info@hima.ae

www.hima.ae

Your Winning Formula for Infinite Creative Possibilities! DMS PromoStation is the region’s most innovative design-led Exhibition Stand and Events service provider. Our designs are creative, affordable, innovative, versatile, adaptable and reusable stands which will enable you to attract higher delegate footfall and make your company the envy of all others. DMS Global has been a leader of marketing solutions for every major engineering sector across the globe, hence this enables us to work more closely with your teams to understand your needs, your objectives, and business message.

SERVICES WE OFFER

• Custom Stand Design and Build • Shell Scheme Rental (Octanorm) • Truss System Rental • Audio/Video & Furniture • Dismantling, Maintenance, Storage • Onsight Project Management

SHELL SCHEME & TRUSS SYSTEM

Using a few of our useful tips can give your shell scheme booth or truss display that personal touch, a warmer and more inviting atmosphere, and will help catch the eyes of all passers-by.

VIDEO BROCHURE

Combining the best of print and video into one product. The fusion of LCD with print delivers a powerfully huge volume of information quickly in an engaging and innovative way.

PROMOTIONAL PRODUCTS

Do you have giveaways for exhibitions? Whether it is printed products, merchandise, corporate clothing to increase team spirit, or customized USB’s, DMS PromoStation has cost effective solutions.

CUSTOM MADE STAND DESIGN

There is nothing more individual than a custom designed exhibition stand. Because the stand is specific to your needs, it will certainly be unique and stand out at a show.

Give DMS PromoStation a call today and we will deliver your exhibition stand beyond your highest expectations

Tel: +973 1740 5590 • Fax: +973 1740 5591 • sales@dmsglobal.net www.dmspromostation.net

insight! feature

Interview With

additional pressure reliving systems such as Flares.

Ahmad Al-Khowaiter

This is something we would have never dreamed of a few years ago, by using automation to replace major capital investments in terms of safety. For example, we would have very thick pipes or flare systems in the past that would have to take the full capacity of our wells, if our wells had been uncontrolled for any reason. So, With automation, we have been able to ensure that we can reduce those large relief systems through the benefit of automation. On the other hand, you can see different value propositions, as you go from the well all the way to the petrochemical plants. As you move away from the wells, safety remains core value proposition however, more and more emphasis on productivity, performance optimization and the maximization of yield are added to the safety as main value proposition for automation. And we, as a company have become much more downstream, we started to see more and more oprtunties for full utilization of automation systems such the manufacturing optimization type systems that allow fully integration into the supply chains and marketing providing a heterogeneous integration of upstream and downstream business into one actual business. From an end user perspective, what new advances and capabilities

In your opinion, what is the main value proposition of process automation technologies?

For process automation technologies, safety is very important. That is the first value proposition, more than anything else. Safety systems in automation right now are much more revolutionized and advanced whereas they were previously in a hard wired solid-state or even before that, mechanical safety systems. HIPS are now used a replacement of the mechanical relief system. The second value proposition is optimization. Without automation, optimization would be practically impossible. Automation has allowed tremendous gains in productivity in process plants, especially the more complex a process plant. We realize more benefits of optimization technologies in downstream process with more advanced and complex in petrochemicals. For example, in the Sadara program, Saudi Aramco together with our partners Dow Chemical see huge optimization opportunities and benefits that can capitalize in advanced process Automation and control systems above and beyond basic process control that we 20 | Automation INSIGHT! | decEMBER 2013

would you like to see? And what are Saudi Aramco’s main issues?

For end user perspective, I would say our priorities change over time. Initially our priorities were standards, standard systems, easy maintainability, ease of configuration etc. So we were already looking for the two of those that came with the right tools to allow quick and easy configuration. That was our past and main focus … ease of maintenance and performance of the automation tools and other actual controls. They had to meet our very high performance requirements for automation controls. For example, scan rates and all, typical details of control systems. From an end user’s perspective, I would say our priorities change over time. Initially our priorities were standards, standard systems, robustness, easy maintainability, ease of configuration etc… So we were already looking for the two of those that came with the right tools to allow quick and easy configuration. That was our past and main focus.

used to experiance in typical oil and gas processing facilities. In petrochemical plants and the like, optimized and accelerating start-up times are some of the new operational requirements that are kind of new to us. We have not yet fully utilized automation in start-ups for example. In the past, our start-ups have been relatively manual, and once our systems were in steady state, we then utilized our automation systems to take control, sort of like an auto-pilot. So, what we are doing now is, as we go more advanced, optimizing startups for the more complex processes. The risks in start-up to productivity losses and material losses is greater for more complex processes. Therefore, automation plays a big role in bringing up these complex systems and allowing safe and quick start-up. So, it is a very interesting progression of the benefits of automation, from the very simple upstream process controls, that only focused on safety. So I would say, as you go from upstream all the way downstream, the value proposition changes with automation. At the very-very far upstream, where the process is mainly related to operation and Automation of Oil and Gas wells, 90 per cent of their value proposition is safety. We are realizing tremendous capital and Operational savings through the utilization of high integrity pressure protection system (HIPPS) which allows safey operation through the use of existing pipelines network and process facility without the need to replace and/or add additional mechanical protection or

Reliable in experience and technology. Endress+Hauser has a wealth of know-how, products and services to support the Oil & Gas industry. Whether upstream or downstream, we tackle your specific challenges with a spirit of partnership and enthusiasm. Our expert engineering, open standard technology and reliable field instrumentation can enhance and improve overall plant safety. Factory-trained staff are available worldwide to support you throughout the entire life cycle of your plant. Endress+Hauser, partnering to save your time and money.

Endress+Hauser Instruments International AG Middle East Support Center 7WB, Office 2100 Dubai Airport Free Zone

P.O. Box 293828 Dubai United Arab Emirates Phone +971 4 253 51 00 Fax +971 4 609 18 11

info@ii.endress.com sales.inquiries@ae.endress.com www.ii.endress.com

december 2013 | Automation INSIGHT! | 21

insight! feature Today, our priorities have changed a little bit more. Now, we have gone beyond the basic automation and we have a little bit higher level concerns. One of our major concerns recently is cyber security. I think in the past these control systems were treated as islands for each facility and security wasn’t a major issue as long as you had physical security of your plant or facility, you are pretty much sure or ensured of security for your facility. Today, because of the complexity and the open benefits of optimization, these facilities become integrated. The data has to be integrated into larger optimization systems. For example, we have our oil supply and planning systems, logistics type and supply chain type control systems that optimize the overall production around our company. This integration now creates vulnerability as well. So you have the benefit of the data, but then you have the risk that comes with these internet type networking systems. So we have a big concern about the software security, maintenance of the security and the standards and the minimal requirements that are implemented within that software. So we are very concerned with the level of priority for cyber security. It has not been to the standard we feel it should be with different vendors and in the industry in general has not been taken seriously in the past. I think now there has been a push to implement it. I think that we have to take it seriously as an industry. We have to start looking at creating standards around these areas and minimum requirements that all vendors have to meet and even the industry needs to start looking at developing the skills needed to maintain these type of systems. I mean it is rare for, I believe, an operator to have cyber security experts in the control system field. And I think we will probably be the first to start that kind of capabilities and skill set for that kind of a job. But it is needed it is necessary, and I think the industry is waking up to that. And we had our own rude awakening to that, although luckily it was on the business side and not on the industrial side. But we are taking that lesson seriously and we are applying it to our cyber security, our control systems and we are going to make sure that we are ahead of the industry and we want to push the industry in that direction as well. Would you say the biggest challenge of cyber security is that the threat changes every day since everyday something new comes along?

22 | Automation INSIGHT! | decEMBER 2013

insight! feature kind of industry solutions. We are coming up with some ideas and we will be working with other partners and I am sure we will come up with good solutions. Cyber security has no boundaries. So, are the national oil companies in the region talking more to co-ordinate?

We have gone beyond the basic automation and we have a little bit higher level concerns. One of our major concerns recently is cyber security. Today, because of the complexity and the open benefits of optimization, these facilities become integrated. The data has to be integrated into larger optimization systems. Definitely you can never rest. There is no question about it. The threat is evolving and you have to evolve your defenses. That is why it is kind of contradicting the control system philosophy in the past, which has been “If it works, don’t change it”. Basically keep it. We have normally tried to freeze as much as possible control systems software in order to ensure that there is no major changes once you have got the bugs out of the initial stage because that ensures that you do not have any lock-ups and problems in the future as during the operational stage, it is very critical.

We are talking. For example, we started with first of all with all of our joint venture partners on cyber security. We are talking to the major stakeholders in the kingdom. We have discussions with Saudi Electricity Company (SEC), Sabic and all the other major players in the country. We are also talking to international players as we have had discussions with IOC’s. We are looking at increasing those discussions with other IOC’s. Definitely NOC’s is a great platform for that kind of collaboration. For the next agenda, definitely we need to have discussions with NOC’s. We have had discussions with major players outside of all the industries like major multi-national companies that have faced similar types of issues. So, we believe that it has got to be collaborative. I agree that all companies have specific and very similar needs and that’s where I think we need to work together and come up with solutions. Where do you think the technology trends in automation sector are going?

I think as we achieve relatively comprehensive automation at the lowest levels, and at the control systems levels, there is a need to leverage all these investments that we have had in the field with better tools for optimization. We need to have easier to utilize, easier to maintain advanced controls and optimization tools. We have seen the earlier wave of optimization. It has been pretty manpower intensive in terms of configuration and maintenance for these optimization tools to really maximize their benefits. We need to see more effort on the simplification of these tools, the ease of use and the final and maintenance of these tools. I think definitely optimization has been wonderful. But it is not any good if it is offline. And so I think ways of utilizing and maintaining those tools and keeping them operating is an area where we need to see some improvement from other markets. I think the other area I would like to see some effort is data reconciliation and validation… you know optimization is only as good as the quality of the data that is going into the optimization.

Now we need to keep updating and have the ability to have security systems and features updated and improved continuously while ensuring the stability of the basic platform. That is a challenge. It is a challenge the vendors and software providers for the automation will have to address. They will have to look at some of the data solutions like: Can you dis-engage the security from the stability of the system? Can you create network architectures that allow you to maintain stable platforms, but isolate that from the network security? There has got to be some, and I think standards allow that to happen. I think you can ensure inter-operability between these different systems with standards. So, standards can stay stable and can stay relatively stable over long periods of time, whereas you can change components. So, it does need a re-thinking of the whole architecture of automation. I think we do have to start re-visiting our networks for example right now, re-architecting our networks. That will allow us to isolate the few components of security from the operational stability. Right now, if you try to use the same software platform, perhaps you will have some contradictions. So, this is kind of a challenge that we are facing and I think it can be solved if we all work toward some december 2013 | Automation INSIGHT! | 23

insight! feature Collecting all that data, sometimes gives you the impression that you have valuable information. But in fact it could all be useless if the instrument is out of calibration for example. So, the value of more intelligent devices to be able to validate the data and make sure those optimization tools are really receiving the right information. In the past, it has been a manual process to be able to check the calibration or to make sure that the data is accurate. I think we have to put more intelligence into our lower level instrumentation to be able to ensure that there is real data that can be utilized for optimization. I think that is definitely an area. These kind of tools haven not been utilized because they really need experts to be able to utilize them. For large companies such as ours, we have millions of data points per hour everyday. We cannot afford to validate that data continuously and that’s where I think the automation can improve. Another areathat is very exciting, and surprisingly, it is an area that was interesting years ago but nothing really came up in terms of automation tools and techniques and that’s the testable prediction. I think these testable tools, with all these incredible data we can move toward modeling. The benefit of modeling is that it allows you to predict with minimal data. That is the benefit of modeling because a model is a prediction based on some reality that you are measuring. Actually we have to move away from the model centric optimization, automation and prediction that we have been doing in the past. We did that modeling because we did not have enough data. Now we have got so much data. The best tool is the statistical tools because they allow you to cut through a lot of the errors that are in that data validation (like I mentioned before …. the challenges of data validation). And really cut to what is important to look at for prediction of, for example failures. This is really exciting and we have had good success with it and I am really excited because we have so much data now. We have these instruments that are bringing on these data every second, millions of data points from all of our facilities. The only really manageable tool used in this case would be statistical type tools because it complex relationships that we are looking at. And this is something that I think would be great for research and collaboration with universities As 24 | Automation INSIGHT! | decEMBER 2013

insight! feature well as companies that are interested in coming up with new tools, that would be very valuable to companies. This is an area I think is under research and under implementation. We are doing some good work in but I think there is a lot of room to do. I think the processes have become so complex now that the model based projection isn’t going to work. I think we need to have statistical tools to allow us to do so many predictions and failures and really raise the ability of our facilities by preventing these failures. Things like trips that could have been avoided if you have just been looking at this one data point. Humans can’t look at that one data point among thousands of data points that we have in our control systems that our humans are supposed to watch. But a statistical analysis would have picked up that anomaly. That’s what I think is really exciting and we are finding some really good results with that approach and I think it’s something new to the automation world to incorporate statistical tools for prediction or failure and its something that I think is going to be next new wave. We went through the model protections control, the advanced controls and optimization. We started with basic controls, went through advance controls, automation model predictive controls. Now I think we are going to be looking at the statistical predictions that will give us things like something very difficult to measure, but at the same time, will give you a great indication and very important for the life time of your facilities like corrosion.

these tools in the automation world for the first time. So this is an area where we always have been leading edge users or bleeding edge users if you want to call us that. We tend to do lot of testing before we put something in service on line. We have a lot of capabilities here. For example, prototyping and testing. The best examples is the Engineering Solution Center (ESC) where we can test latest tools, we bring in vendors, researchers and we do some amazing things with that center where we have access to all of our data and we are able to test these tools on that data in a safe environment without affecting our plans and really being able to see and to prove solutions. We feel we are cutting edge in the way we adopt new techniques and software and systems and automation technologies and the way we test them. I have to admit that we are more conservative in our standards, which is necessary for operating facilities. You don’t want to be one of those bleeding edge technologies. We are little bit more conservative. But we work with our industry partners to those bleeding edge technologies and turn them into reliable tools that we can use. So, I feel the way we can help the industry is by piloting and testing the technologies and giving them our challenges and working with them to come up with solutions.

So could you call Saudi Aramco pioneers?

Absolutely, it is recognized by the industry. We are pioneers. We like to test things and we like to propose new ideas. We have a lot of IP. For example, in the HIPS space, we are leaders in the high integrity protection systems. Another thing that I was mentioning before is automation on the upstream side, especially automation in general. But automation in upstream side is focused on the safety proposition which has really given us huge value in terms of savings of capital expenses and capital cost. So, that area we have been the pioneers in fact, I would say the main players in that area. We have a lot of IP in that area, we are working and leading in developing the standards for that and definitely we really network in other areas where more followers … I would say bleeding edge users of other systems. Definitely we have a lot to contribute. Another example is Saudi Aramco was the very first company in the region to install FOUNDATION Fieldbus (FF), and the first company in the world to develop an engineering

Statistical tools to predict corrosion are very interesting areas of research. So to predict failures due to corrosion is something that I think would be an exciting thing to look at. The idea of applying statistical tools to predict failures of rotating equipment, this is always an interesting area that I think we had very good success with in some of the tests and implementations that we have done. So this is the kind of new wave and I think with the university research and industry players should start looking at how to implement these type of tools. We are excited about them. We just spoke what direction you would like to see the industry going, what is that Saudi Aramco themselves doing to promote new technologies and how will the automation sector as a whole benefit from this?

We do a lot of piloting and testing of the latest tools out in the market and now in that we develop our own tools in many cases. We were probably the first major company to apply a data historian platform across the company back in the nineties. We were also one of the first companies to apply DCS (Distributed Control Systems) when it first came out in the seventies or eighties. We are really first movers when it comes to control system technologies, advance controls and modeling. I mentioned the statistical method; we are very much involved in statistical methods.

We are working with non-traditional companies who are not in the oil and gas or the automation space to bring some of those tools from the other industries into the automation world. We are testing december 2013 | Automation INSIGHT! | 25

insight! feature

standard on FF. We have been huge supporters of FF from day one, because we see the value and the Wherever we face a major challenge ahead of the industry, we benefit. And now the FF technology is a mature usually find our own solutions in collaboration with the industry and and recognized technology. We have been very pro we like to capture the IP if we can and share that within the industry in adoption of new so that we can have a technologies; we have solution for the industry. been always trying to The automation industry, especially the local update our standards You talked about industry, is a good fit for small and medium standardizing within to allow the use of these enterprises and there we have a platform of loans, Aramco and Saudi new technologies as venture capital. We are willing to invest in those Arabia. But is there soon as they prove companies, substantial amounts that will enable ways to work with themselves. We drive the other NOC’s of the technologies as them to serve us in the industry. the standardization much as we can where throughout the region? we see the value. We think it is great that Saudi Aramco don’t just treat its vendors as suppliers, you actually work as partners on many occasions. Does Saudi Aramco ever develop its own technology internally without outside support?

We work together as partners to implement the technologies. But we have done a lot of our own internal works. For example, the smart ZV. It’s a new concept for the whole industry and it’s a technology that allows you to do online testing of our safety isolation valves. This is a breakthrough for the industry because by doing online testing automatically for the safety valves you really tremendously increase the reliability of these systems, which are a critical layer of defense for the safety of your facility. That was an invention by one of our specialists. Then we identified partners that would actually manufacture these systems, and now it is becoming industry standard. They also happen to make some great savings in terms of costs so they are very attractive proposition for any company that is seeking in oil and gas and petrochemical industries. This is the standard we created out of our own IP. We are doing the same again in HIPS, a similar kind for the high integrity pressure systems. We are developing all that IP internally. We have done our own testing. We have invented many systems for high integrity protection systems. We are writing the standards on that. We are really leading developing our standards and we are standardizing a process and this is also making major capital savings and increasing the safety. So we are getting two for one IP’s. We have IP across the board and automation in general. 26 | Automation INSIGHT! | decEMBER 2013

We work with vendors who supply all over the NOC’s. For example, Emerson does safety valves using our IP. Collaboration is more through the vendors than anything else and through the standards development. we are also together with NOC’s and IOC’s on the standards bodies. Standards bodies membership is across the oil and gas world. A big area of collaboration is how do you adopt and modify these standards to allow these new technologies. That is where I think the main collaborations are. It is not in specific research projects. It is more after we have proven something, how do we share that in fuller standards and implement it with standards. Now standard organizations is the best way because you get the best in minds from all these different industry vendors, oil companies etc. So you really get to have something that makes sense for everybody, as opposed to one particular unique solution, which then you try to adapt to a different situation. It may not work directly. So you really need to take the essence of your solution in the form of a standard. And everybody can agree to it.

see the local content to increase in the area. We have procurement policies now, which are looking at more incentives for the local content. We have a number of labourers, entrepreneurship platforms which actually support entrepreneurs with loans and venture capital to support those kinds of small and medium enterprises that are in the automation. That’s actually a very good fit. The automation industry, especially the local industry, is a good fit for small and medium enterprises and there we have a platform of loans, venture capital. We are willing to invest in those companies, substantial amounts that will enable them to serve us in the industry. So we have got a number of interesting start-ups that are actually working with our equity and loans that have started up in the country. In your opinion, how can the ISA Automation Conference and Exhibition in Dammam help from the technical and economical point of view to Saudi Arabia? One other thing I would like to add is that, because Saudi Arabia is such a huge market, typically events here focused just on the Saudi market. But this event is the Europe, Middle East and Africa event. So how do you feel about Saudi Arabia hosting such a regional event?

I think this is a great precedent. I think we have tended not to hold these international events as much due to perceptions. I think this is a great event to hopefully disperse some of those perceptions and try to really show that we can host international events, to show that we can bring in participants from around the world. The advantage of an event specifically in Saudi Arabia is that we have the biggest market in the Middle East. And you are seeing first-hand what that market

is. And you are getting a chance to see what drives this market. You need to talk to a lot of people to understand this market and understand what its needs are. To me this is a golden opportunity for participants from around the world, it is important to understand those challenges and the opportunities because you can really get some major rewards if you understand the market well. And those who have really benefited tremendously and they were the ones who were here first. If you look at the biggest revenue earners, multi-nationals in this region are the ones that were here in Saudi Arabia before everybody else years ago. And I’m talking about a very early entry … People who have been around almost as long as Saudi Aramco has been within the region. So those companies benefited by understanding the market. Part of understanding it is talking to the people who make the decisions and understanding. Having everybody in one event like this is a golden opportunity. We really will not be able to see all the automation players, companies and decision makers in one place rather than just representatives of those companies which you would see in a typical conference outside the region.

It is almost like a legal compromise. It really serves a great purpose of making sure of the most important aspects of improvements or innovations that each company is able to bring or adopt together and then you capture the essence. It reflects that and it is a stable, more secure or reduced risk approach to the sharing of innovation. What is Saudi Aramco doing to promote and encourage local content when it comes to automation technologies?

In general, not just automation technologies, we are very supportive of the local content and our policies are changing as we speak. Here in New Business Development for example, I am very much involved with our procurement groups on changing our procurement policies to recognize and to enable local content maximization in the kingdom, for a number of reasons of course. We want to see our supply chain as close as possible to us here. We want to allow innovation that we develop as well implemented as quickly as possible. So there are a lot of things that drive us to december 2013 | Automation INSIGHT! | 27

insight! feature

Interview With

with the ISA Saudi section in these issues?

HUSSAIN QAHTANI

We are completely supportive towards the ISA section as a matter of fact, the Chairman and most officers are from P&CSD. We, the Process & Control Systems Department (P&CSD) have the technical authority for Saudi Aramco in terms of process automation. We are supporting and we are expecting such chapters will help to disseminate all of the knowhow within Aramco and beyond. It will also establish the platform in Saudi Arabia and within the region whereby they can regularly bring experts in order to exchange technical information to help us to develop and enhance process automation and operating facilities. Is there any advice you would like to give the attendees of the conference and exhibition on how they can maximize the value they get out of the event?

What was the main driver behind Saudi Aramcoâ&#x20AC;&#x2122;s support for the ISA EMEA Automation Conference and Exhibition 2013 in Dammam?

localize such events to maximize the benefits for our engineers. We look forward to this event being successful in meeting our objectives. I hope that every individual who attends this event walks away with a lot of information and builtnew relationships from the networking opportunities provided from the exhibition.

First of all, we as Aramco support such events because we believe they establish a good platform for technical people What role should ISA There is a big challenge for process automation and its local section like engineers to come together under one since the expectation of users are high as they in Saudi Arabia be roof to exchange ideas, believe we can do more with less. We are looking playing to promote the problem solve and for less interference between the process and the automation profession and technology? discuss the know-how of the best practices. people, but through robust systems. It will be a forum for Honestly, there is a leaders and technical experts, which will add a lot big challenge for process automation since the expectations of users of value in establishing networks as well as giving are high as they believe we can do more with less. We are looking opportunities for people to raise any concerns they for less complex interaction between the process and the people, and may have. through robust systems. Moreover, cyber-security is another major challenge. Therefore, I look at the ISA event as a platform to take us In addition, this will be the first time the to the next step to meet the objectives of advanced automation. Kingdom hosts such an event. Saudi Arabia are undertaking a lot of huge projects and we need to How is Saudi Aramco and P&CSD department in particular, working 28 | Automation INSIGHT! | decEMBER 2013

The attendees can take full advantage of having this event in Saudi Arabia. In terms of the logistics, it is an opportunity for the people based locally to attend. Also, the conference technical committee have selected excellent topics and invited technology leaders to present these topics. So, the attendees have to take full advantage of this and listen to them by attending the technical sessions and most importantly, develop the network. Along with the conferences, there are some technical courses arranged. For the vendors exhibiting at the event, how could they best promote themselves to the visitors?

The way we try to deal with the vendors, especially for process automation is not like a relationship of a buyer and supplier but rather that it is a partnership. I think this event brings an opportunity for them to demonstrate that relationship. Therefore, we are encouraging them to bring the latest technologies in their arena to this conference. The event will also give them the opportunity for the people to know what they have done lately in terms of technology and I am sure it will be a win-win situation for both sides.. This will help attendees to understand what they have done lately in terms of technology and also to explain the technologies that have been developed. december 2013 | Automation INSIGHT! | 29

paparazzi | Automation

Automation | paparazzi

MEPEC 2012

Bahrain

29 September - 2 October 2013

DLPS - Parvez Kashmiiri Endress + Hauser - David Hewitt

Saudi Aramco - Ameen Dossary

Dresse Al Rushaid - Fahad Al Shammary

Emerson - Sami Sahtila and Danielle Aychouh Turk - Joven Zamudio

Invensys - Ishtiaq Aboobacker Al Abdulkarim - Paolo Poero, Bruce Boreque, Ramesh Pillai & Abdullah Al Shamri

Al Mazroui Engineering - Drew Steedman

30 | Automation INSIGHT! | decEMBER 2013

GE Oil & Gas - Jamana and Omar

Axens - Joseph Ibrahim

Yokogawa - Aneesh Mohanan Nair

december 2013 | Automation INSIGHT! | 31

industrial automation and control

Progress you trust

The SIMATIC PCS 7 Process Control System In process plants, the process control system is the starting point for optimal value added: All procedures and processes can be operated, monitored and influenced with the process control system.

The process control system is the interface to the process, and it enables safe process and plant control and at the same time serves as the central database from which further optimization potential can be tapped into. The more powerful the process control system, the more effectively this potential can be used. For this reason, performance is in the foreground with SIMATIC PCS 7, alongside scalability, flexibility, and integration. Starting with planning and engineering, the process control system offers powerful tools, functions and features for costeffective and efficient plant operation through all phases of the plant life cycle.

Performance through integration Integration is one of the special strengths of SIMATIC PCS 7 and is evident in many aspects: • • • •

Horizontal integration into TIA Vertical integration into hierarchical communication System-integrated tools for engineering tasks Integrated functions, e.g. for batch process automation, process safety, energy management, telecontrol tasks, etc. • Integration of the fieldbus level including drives, switchgear, etc.

Horizontal integration

A system for integrated automation of the entire process chain, from incoming raw materials to outgoing goods – this is one of the decisive advantages resulting from the seamless integration of SIMATIC PCS 7 into Totally Integrated Automation. The process control system is mainly responsible for automating the primary processes here, but it can do very much more: All ancillary facilities such as the electrical infrastructure in the form of low-voltage or medium-voltage switchgear, or the building management system, can also be integrated into the system. Integration of selected SIMATIC standard components – automation systems, industrial PCs, network components, or distributed I/O units – into the process control system guarantees optimal interaction of individual components, and secures economic benefits such as simple selection, reduced stock keeping, or global support.

december 2013 | Automation INSIGHT! | 33

simple math

Vertical integration

The hierarchal communication of a company encompasses the field level, the control level, and the process level, up to management and enterprise resource planning (ERP). Thanks to standardized interfaces, based on international industry standards as well as internal interfaces, SIMATIC PCS 7 is able to provide process data for analysis, planning, coordination, and optimization of plant sequences or production and business processes – in real time, and at any location in the company!

Central engineering SIMATIC PCS 7 convinces with graded functional diversity, consistent operator control philosophy, and uniformly structured engineering and management tools. A central engineering system with a coordinated range of tools for integrated system engineering and configuring of batch automation, safety functions, material transport or telecontrol systems creates value added over the entire life cycle. Reductions in configuring and training costs result in minimization of total cost of ownership (TCO).

• Batch process automation (SIMATIC BATCH) • Functional safety and protection functions (Safety Integrated for Process Automation) • Route control for material transport (SIMATIC Route Control) • Telecontrol of remote units (SIMATIC PCS 7 TeleControl) • Automation of electrical switchgears (SIMATIC PCS 7 PowerControl)

Functional diversity

Further additional functions that are also integrated, or can be integrated, seamlessly into the control system make optimization of processes and reductions in operating costs possible.

Depending on the typical process automation or customized requirements, SIMATIC PCS 7 can be functionally expanded for the following, for example:

SIMATIC PCS 7 has, for example, tools for energy and asset management, and it offers higher quality closed-loop control functions, as well as industry-specific automation solutions and libraries.

Value added custody transfer. Innovative technology

Integrated products Guaranteed accuracy and compliance

It adds up. Innovative technology and seamless integration with plant-wide automation and security makes transport, storage and distribution of oil and gas safer and more precise. Count on Honeywell for safe, simple and accurate hydrocarbon logistics. It’s simple math.

34 | Automation INSIGHT! | decEMBER 2013

control system cyber security

Control System cyber Security

Can The Smart Oil Field Survive without a Smart Cyber Security? Author: Ayman AL-Issa, Digital Oil Fields Cyber Security Advisor, ADMA OPCO Whether it is called a Digital Oil Field (DOF), Intelligent, Smart, or the Field of the Future, the DOF is all about how we operate our fields in the future for achieving better decisions, reducing risks to health, improving Safety, lowering operational costs, attaining more oil recovery, increasing production by connecting remote sites together, moving to real-time or near real-time way of working, and having the teams work together. While oil and gas companies seek to build the new green fields as Smart Oil Fields (SOF) realizing the great achievements that would be obtained from going into this approach, an important factor

that is still not being given the appropriate attention is the significant need for these fields to have an intelligent digital cyber security at the core of their Industrial Automation and Control Systems (IACS). Although those companies concentrate more on smart field devices, MPFM, asset management, and so on when we talk about these fields, real-time data acquisition plays an important role. Integrating the industrial networks with business networks is the main mean for getting the real-time data. Recent automation systems are built on open standards such as Windows or TCP/IP. Realizing this nature and recognizing the above facts dictates that the present cyber security controls that are used within the latest automation systems are no longer enough to ensure protection of these automation systems especially the ones that are part of the

critical infrastructures. Being built on open standards makes these automation systems more vulnerable to cyber-attacks while in reality they are difficult to protect due to their presence in production environments that can’t easily cater for frequent changes required by cyber security controls. It is important to realize early that those fields are in need for a cyber-security defense in depth model more than any existing IACS infrastructures. However, we hear a lot from here and there about industrial cyber security defense in depth techniques, but the reality is that almost all what is talked about cannot rise up to the meaning of the world “real”. This fact worries when we have to admit that the bad guys are much ahead and more intelligent than all available security solutions. Asking the question “do automation vendors heal the wound with the right medication and?” is a question that needs great focus. Industrial cyber security is not automation vendors’ core competency and this is not something to hide. Cyber security vendors also need to focus and do lots of efforts to ensure that they can provide solutions that are capable to address the kind of continuous production environment that is within production areas. What can help is to prepare the ingredients of the cake before

preparing it. We need to clearly understand control systems and cyber security, mix them together and provide the right solution. This means that those who can participate in drafting the solution shall be those who wear two caps (industrial and cyber security). Although there would be much more to think through, considering the following factors could pave the way for implementing a real acceptable cyber security solution to help protect the smart oil filed from the emerging cyber threats: • Consider “cyber security by design”; Industrial Cyber security shall be considered at the design phase of building the smart fields by engaging this within the Front End Engineering Design FEED phase. • Encourage real partnerships between automation and cyber security vendors to help provide cyber security solutions that can fit within the industrial infrastructures. • Make the defense in depth model a real defense

Temperature is our business

The VortexWell Thermowell • No velocity collar required • Helical strake design • Stable pressure field

36 | Automation INSIGHT! | decEMBER 2013

december 2013 | Automation INSIGHT! | 37

Innovation at Okazaki | okazaki-mfg.com

Control System cyber Security in depth one. Talking about this needs multiple articles to cover, and still we will be behind the bad guys. • Understand and absorb the fact that there is no cyber security solution that is a bullet proof one, so there is need for solutions that would provide deep vision of what is happening in the industrial infrastructure and use the behavior changes as clues to know if there is a mouse in the house or not. • Don’t forget to build upon the softest weak link, the human factor, and also improving processes, policies, etc. but I always advise that we shall not focus only on building a huge policy and give less attention to the real work. If we dive into policy and consider it a great thing alone, then we better draft a policy that tells the hackers that they are not allowed to hack the systems and steal information or disrupt the operation!!! • We need to ask ourselves how we are going to

38 | Automation INSIGHT! | decEMBER 2013

Control System cyber Security

operate, maintain, and support cyber security within the long life span of the field (20 to 30 years or more). It is important to early realize that this would not be possible without the three players putting their hands together: first, the customer who shall ask and know what he needs; second, the automation vendor who shall deeply consider the need for cyber security within their control systems; and third the cyber security vendors who should understand how the automation system game is played. Oil and Gas companies need to share and exchange such experience and design their smart fields with cyber security at the right time as cyber security can never be good if it is done as a make up at the end of these projects. There is a lot to talk about in this regard, and despite the dark clouds, there is a path that would lead to acceptable level of cyber security that suits those smart fields. Certainly, cyber security shall be at the core of the intelligent field, and we need to remember that when we talk about industrial cyber security today with the existence of real major threats, we talk about protecting human lives, environment, critical infrastructures, and protecting smooth operation of the fields. We need to remember that one major cyber security related accident is similar to walking on mines where the first mistake is the last mistake.

december 2013 | Automation INSIGHT! | 39

wireless and industrial communications

Wireless Technology Applied to Condition Monitoring Authors:

Stuart Courtney, SKF, Senior Application Consultant Marty Herzog, SKF, Marketing & Business Development

Abstract Condition Monitoring of rotating equipment is a common practice throughout the oil and gas industry, with the objective to monitor, detect, analyze and diagnose machinery faults. Critical machines (turbines, compressors, large motors, etc.) are normally equipped with on-line condition monitoring and protection systems. Balanceof-plant equipment (motors, pumps, fans, etc.) generally are not. This machine category represents well over half of the rotating machine population and consumes a significant percentage of a maintenance budget. Such machines are normally

monitored with portable data collectors because it has been either impractical or uneconomical to install and maintain a permanently wired system. However, the situation has now changed. A new breed of wireless condition monitoring systems promises to bridge the gap between the application of wired systems and portable systems for balance-of-plant applications. This paper will explore the challenges and rewards of wireless condition monitoring through reviewing wireless technologies, cost benefits, constraints of wireless systems and the benefits that emerge for condition monitoring of balance-of-plant machinery.

Overview of Condition Monitoring Condition monitoring has been the backbone of maintenance strategies for the last few decades. Widespread application of this technology has allowed facilities across the oil and gas industry to (a) optimize maintenance intervals, (b) extend production schedules and (c) avoid unplanned downtime. The principal parameters measured are vibration and temperature due to their direct relevance to the condition of rotating machinery, with vibration data employing FFT spectrum analysis having a higher diagnostic value. Machine condition data is collected using permanently installed sensors as part of an on-line system or with portable devices requiring manual collection. Online systems allow continuous machine vigilance and can be configured to protect 40 | Automation INSIGHT! | decEMBER 2013

Wireless and Industrial Communications basis. Therefore, changes in machine condition or machine failure can often be missed in between the data collection periods. The determination of which technology to apply on which machines is rooted in the local plant maintenance strategy, standard industry practices and the sheer economics involved. While most reliability engineers would like to have online systems applied to more machines, online systems can be costly to install and maintain, especially in facilities with hazardous areas that require very particular wiring and installation practices.

Figure 2: General application map for condition monitoring

Portable systems used in hazardous environments must meet strict intrinsic safety ratings and sometimes necessitate “hot work” permits, depending on the type of machine analysis to be performed. Moreover, collecting data manually has other drawbacks, including worker safety issues, consistency of data, timeliness of data, etc. Portable systems will always have their place as part of condition based maintenance strategy. But it is clear that increasing reliability requirements and pressures to reduce maintenance spending, combined with enormous populations of balance-of-plant machines justifies an investigation into the development of a new device. To bridge the gap between the ideal world, where every machine is connected to an online system, and the current state, where this is not practical or economical, would require that a device cope with five principal challenges. If these could be overcome, then it would be possible to produce a wireless device that is suitable for application in the oil and gas industry across a larger percentage of machines. While each of these parameters individually represents a challenge, fusing together a system able to satisfy all of them requires careful

Figure 1: Typical condition monitoring data showing overall vibration and FFT vibration spectrum

critical machinery via automatic shutdown features. Portable systems require physically visiting each machine and spending several minutes collecting data from multiple sensor locations, typically on a monthly

Figure 3: Technology factors to be addressed

balancing of trade-offs. Fortunately this “fusion” has been achieved and results in the following benefit creation across several technology domains.

Technology Issue

Oil & Gas Industry Requirement

Benefit

Low power circuitry

ATEX Zone 0 compliance

Can be applied across plant

Battery technology

Up to 5 year life (daily readings)

Longer term peace of mind

Dimensional footprint

Mountable on machine or skid

More practical installation

Wi-Fi Mesh Network

Standard IT compliance

Less costly IT deployment

Vibration (FFT) & Temperature

Accurate machine condition

Early indication of potential problems

Data integration with portable and online system

Complement to existing condition monitoring program.

More efficient deployment

Table 1: Technology challenges related to Oil & Gas applications

The remainder of this paper will focus on the wireless aspect of the challenge. december 2013 | Automation INSIGHT! | 41

Wireless and Industrial Communications

Why wireless?

Wireless condition monitoring systems must be compatible with the dominant standards in order to gain wide acceptance.

We now use wireless devices in our everyday lives. Many companies are developing wireless capabilities. The benefits of mobility make the use of wireless equipment almost a necessity. We never give a second thought to how we use SmartPhones, tablets and TVs we just accept they work out of the box. Before we look at some examples of how wireless technologies have been used it may help to look at some of the various wireless protocols and systems and also look at what may be available in the future.

Wireless and Industrial Communications

Multi-point wireless devices as well as single-point wireless sensors have been developed and shown to be successful in demanding industrial applications. Another important development in the condition monitoring world has been the ability to share data with process control systems. Changes in vibration levels may be due to a change in operating conditions and without that knowledge an incorrect diagnosis could be very costly in time and production output. It has now become possible to have process control system data available to the condition monitoring engineer. This has been facilitated by such systems as Honeywell Experion and Honeywell

One Wireless. Values such as temperature, pressure, valve position and other plant information can now be compared with changes in vibration levels, thus enabling a far more accurate diagnosis of the problems and therefore enhancing plant operating knowledge. It cannot be emphasised strongly enough how important process control information is to the condition monitoring engineer. Vibration measurements can be significantly influenced by such parameters as temperature and load. If these parameters are not known at the time of measurement, the condition monitoring engineer may make an incorrect diagnosis that could result in a premature shut down or an expensive failure.

Figure 4: Wireless technologies application map

The following chart gives some idea what is available and looks at the various data rates, power consumption and cost of manufacture. Wireless condition monitoring systems are more flexible than a traditional wired network. Speed of installation is much faster than with traditional systems. Users are not fixed to a

network topology or system setup, leaving open the possibility for additions or upgrades. Reduction in installation cost and speed of installation help wireless systems provide a faster ROI. Wires and cables are not practical for many applications, for example, moving or rotating equipment, such as a crane, requires a much more complex and costly installation â&#x20AC;&#x201C; if it is even possible. And oil and gas installations require expensive installation procedures to meet zone requirements.

Wireless Developments Developments in industrial wireless technologies are happening at a frenetic pace. The promise of ubiquitous, low-cost sensors operating over a plant-wide wireless network fuels massive investments by leading technology companies in various wireless applications. One such application is condition monitoring. Wireless devices have actually been available for several years, however widespread market adoption has not taken place due to technical (including proprietary protocols) and cost barriers. It appears, though, that with recent advances in networking, radios, processors, sensors, and power sources it is now possible to overcome these barriers. A rough estimate for the cost of installation of on-line sensors can be made and for typical industrial applications, it can be as high as 15 times the cost of the accelerometer. For oil and 42 | Automation INSIGHT! | decEMBER 2013

gas installations it can be greater than 20 to 30 times the cost of the accelerometer. The use of a wireless device would equate to an approximate saving of around $1500 per measurement point. Condition monitoring (using dynamic data e.g. vibration) presents unique demands on wireless sensors, networks and associated components. Some of these include high bandwidth; good dynamic range; low noise; higher-level processing capabilities; ability to capture data at the right time, etc. When operating as a self-contained unit (commonly battery-powered), which is most desirable, options are further limited by available power and requirements for long service life. The devices or sensors, as well as the wireless network components, must also cope with conditions commonly found in the industrial environment such as exposure to water and/or elevated temperatures, electrical interference, hazardous area classifications, obstructions, and physical location/distance. Network security must be sufficiently addressed.

Figure 5: Typical condition monitoring architecture across a refinery

Wireless standards currently in development (in particular Wireless HART and ISA 100.11a) will shape the infrastructure in which the wireless condition monitoring systems need to operate.

Wireless vibration sensors can now be connected through the same protocols as process data and integrated into the condition monitoring system through the Distributed Controls System (DCS). Conversely the vibration data can be shared with the process control data. december 2013 | Automation INSIGHT! | 43

Wireless and Industrial Communications

Wireless Technologies Applications Examples Oil Tanker Application – 802.11g WiFi Network A substantial number of wireless monitoring units are fitted to ships machinery to enable data collection for the purpose of obtaining exemption from classification inspection by the use of condition monitoring systems – with considerable savings to operational efficiencies. This was carried out as a joint project between SKF, a leading automation company and a leading oil company. (The new generation of the system has since been released, specifications shown below.) • 4 dynamic channels and 4 static channels (Supports 4 combination sensors -- accelerometer & temp) • Tacho / Digital inputs 1 digital, 1 analog • Battery or 24 VDC operation, External wake-up from PLC • ATEX / IEC Zone 2 rating, IP 67 enclosure • Up to 12,800 line FFT, 40 kHz Fmax • Proprietary SKF bearing detection algorithm • Wireless Security (WEP/WPA/WPA2) • Temperature range -10 to 60 deg C • 120 x 220 x 90 mm

Oil Tanker Application – 802.11g WiFi Network North Asian Refinery: A newly built with an annual capacity of 12 million tons per year (275,000 bpd). The single train plant was designed to process high-acid heavy offshore crude. Pump Monitoring Project • All critical machinery fitted with protection systems (API-670) by the EPC, but no on-line machinery condition monitoring system. • No portable vibration analyzer program equipment is monitored using bi-weekly operator rounds, collecting vibration and other data using simple hand-held devices and industrial PDA’s. • After too many unplanned outages on pumps, an RCM study determined the need to add an online surveillance system on all pumps above 500 kW. • Requirement was for more frequent datacollection of vibration and temperature at pump bearing locations than would have been possible with a portable, manual data collection system. Multiple sophisticated wired vibration based surveillance systems are on the market, but all 44 | Automation INSIGHT! | decEMBER 2013

come with a significant installation cost: • System hardware & software • New cabling and infrastructure • New power distribution • Project engineering • Installation labor and materials • Installation restricted to plant outages. Technology project to trial practicality of wireless system coverage: • Single processing unit – 20 pumps (60 sensor locations) • ATEX Zone 2 hazardous area. The Solution Sensor system for machine condition monitoring • Monitor plant areas uneconomic to cover by wired or walkaround solutions.

The Future Future trends will include sensor networks with low power sensors sending vibration, temperature, pressure and many other parameters for analysis. Battery technologies will further enhance the use of stand-alone sensors. Sensors may even become disposable due to the lower manufacturing costs.

Easy deployment: • Avoid cable trays and wiring • Reduced installation time • Reduced project engineering and documentation • A wireless point can be a factor of 8 lower to install than an equivalent ‘wired’ point.

Process industries use various network protocols. It follows that condition monitoring systems will be considerably enhanced if they can reside on such systems and therefore make use of relevant data that will be available to a reliability engineer to make accurate and reliable diagnosis of a changing machine condition. The more consolidated and relevant the data being presented, the better the chance of being able to fix the problem and to ensure that the same problem does not occur in the future.

A network of wireless field sensors using Wireless HART protocol • Open and interoperable communications • Mesh Network to navigate data around obstacles and cover distances greater than the device’s innate range.

Recent announcement of SKF Insight™ represents a groundbreaking innovation that demonstrates just how for this technology can be developed – and it’s no longer that far away. This development allows SKF bearings to communicate their operating

Figure 7: New SKF Insighttm wireless, smart bearing development • Smart components are integrated into the bearing or housing and communicate directly to gateway • Monitor load, lubrication, speed, temperature and vibration • Self-powered, using power scavenging technology

conditions continuously, with internally powered sensors and data acquisition electronics. Installed directly onto the bearing itself, the system will be capable to communicate with the outside world about bearing condition. Currently being applied to large, expensive bearings in ultra-high reliability applications, this technology will eventually work its way into more common applications. december 2013 | Automation INSIGHT! | 45

Wireless and Industrial Communications

Process optimization of DeNOx plant with WirelessHART Authors:

Conclusions Challenges

vMonitor

Creating the Digital Oilfield

Optimizing your Oil & Gas Assets for over a Decade

Optimization & Applications

Wireless sensors will no doubt result in significantly more data being acquired and therefore there will be a need to analyze and store this data. Data interpretation using decision support systems and data reduction methods will need to be developed and deployed. Wireless systems will change the way we approach machine condition parameter data collection. Ease of deployment of wireless systems connected to process control systems will be driven by users, not by suppliers of technology solutions. Performance monitoring will become more closely integrated to condition monitoring. Using process and control system information will enhance the way we analyse vibration data. This will allow maintenance personnel to determine the cause of the failure of a machine or system component not just change a defective component without knowing why it failed.

Summary Measurement & Automation

SCADA Software

Flow Control

Head Office

Technology Center

15/F Al Masraf Bldg., Hamdan St. P.O. Box 35427 Abu Dhabi, UAE

4321 W Sam Houston Parkway N #110 Houston, TX 77043, USA

Tel: +971 2 6767 965 Fax: +971 2 6767 956 Email: info@vmonitor.com

Tel: +1 713 467 3900 Fax: +1 713 467 3999 Email: info@vmonitor.com

www.vmonitor.com

The wireless world is changing very quickly. The challenge is to stay plugged into the latest technologies and make every effort to develop products and services that best serve the objective of cost effective and efficient condition monitoring systems. Technology’s “early adopters” have already installed simple systems to test the feasibility in their own plants. That “early adopter” period is probably now coming to an end and people are looking for a simple-to-install, simple-to-configure system that uses existing knowledge and decision support systems to manage the configuration and interpretation of the data. This will give real value to plant operators in managing plant uptime and efficiency.

Arne Kroeger, Product Manager Automation, Weil am Rhein, Germany Sarah Caruso, Marketing Manager Fieldbus, Reinach, Switzerland How can a plant be optimally monitored when its measuring points are difficult to access? RSMVA in Basel, Switzerland, has adopted the Endress+Hauser WirelessHART solution in order to provide improved and safe control of the processes in its DeNOx plant. RSMVA, the regional hazardous waste incineration plant in Basel, is owned by the environmental service provider VEOLIA ENVIRONNEMENT PARIS, which employs over 300,000 people in 115 countries in its worldwide network. The plant is operated by the VEOLIA subsidiary Valorec Services AG and is the largest incineration plant of its kind in Switzerland. 32,000 tons of hazardous waste are burnt there every year. In addition to solids, pastes and liquids, the plant processes all gaseous hazardous wastes. The by-product of the incineration plant comprises energy in the form of high-pressure steam and electricity. The steam is supplied primarily to the Novartis plant in the neighboring Klybeck district of Basel. The residual heat from the plant is used to supply the nearby Stuecki Shopping Center and Business Park with low-grade heat. Electricity is generated with a steam turbine and covers roughly a third of the plant‘s own needs. Waste management is not the only activity in Valorec Services AG’s portfolio. The company is also responsible for energy management in the Novartis plants in Klybeck, St. Johann and Schweizerhalle.

The DeNOx Plant When hazardous waste is burnt, toxic flue gases are produced which must be processed before they can be safely emitted to the environment. In order to filter out greenhouse gases and hazardous materials, a six stage cleansing process is used. The cleansing primarily comprises filtering, adsorption and absorption as well as catalytic conversion. On leaving the six-stage cleansing process, the flue gas is fed through the so-called DeNOx plant. Here the nitrogen oxides (NOx) are reduced in a catalyzer and the heat from the waste gases is recovered in a heat exchanger. The recovered heat is used for heating the gases flowing into the catalyzer. The temperature of the flue gas entering the DeNOx plant is about 120°C and must be increased to

at least 230°C in order that the NOx in flue gas can be reduced by the catalyzer. Additional heat is supplied by a gas burner.

Project Background The heat exchanger comprises a great many individual plates with hollowed flow passages. Over time, deposits accumulate on the plates, so that heat can no longer be transferred and the efficiency of the heat exchanger drops. Such deposits have an even greater effect on the pressure loss within the flue gas plant, which is driven by a high pressure blower with a rating of 650 kW. As the deposits grow, the pressure drop across the heat exchanger increases significantly. This has a direct effect on the output of the blower and thus on the cost of running of the plant. Before the project, only the pressure drop across the inlet and outlet of the DeNOx plant had been measured. Thus, it was impossible to exactly locate a deposit and as a result the entire heat exchanger had to be cleaned – a time-consuming and costly process. When it was decided to invest in a new heat exchanger, the concept for plant monitoring was also re-examined. Several differential pressure measurements were to provide more precise information about deposits in the heat exchanger. Due to the cross-flow method employed by the heat exchanger, however, the differential pressure measuring points would be difficult to access and the positioning of the measuring instruments would be a challenge. In addition, several temperature transmitters were to be installed in order to determine the efficiency of december 2013 | Automation INSIGHT! | 47

Wireless and Industrial Communications the heat exchanger. The height of the exchanger, approximately 30 m, also presented a problem. All requirements were solved by acquiring the measurements by wireless.

Endress+Hauser’s Solution The plant - basically the heat exchanger - extends over four stories. On every story, measuring points are installed at different positions on three side walls of the heat exchanger. This facilitated the decision to use WirelessHART, as cabling of the measuring points would have required a lot of effort, time and cost. • • • • • • •

Endress+Hauser delivered the following: 17 WirelessHART Adapters SWA70 1 gateway WirelessHART Fieldgate SWG70 7 pressure transmitters 5 temperature transmitters Pre configuration of the adapters and gateway Factory Acceptance Test Integration into the control system and commissioning

One WirelessHART adapter is attached to each of the already mounted temperature and pressure transmitters. In addition, four adapters are employed as repeaters. Measurements are transmitted to the WirelessHART gateway at 15 minute intervals. An ABB AC 800F Controller retrieves the measurements from the gateway via a Modbus RTU connection and displays them in the control room. The customer has considerable advantages when using wireless technology: • Cabling, engineering and documentation costs were drastically reduced • The system could be commissioned in a very short time • The Modbus configuration was done on-line.

Future Possibilities The nature of a WirelessHART network means that additional measuring points can be quickly and easily integrated in a control system. Thus RSMVA, together with Endress+Hauser, is planning to integrate existing flow measurements via WirelessHART into the control system, which to date were not evaluated by it. 48 | Automation INSIGHT! | decEMBER 2013

Conclusion

Wireless and Industrial Communications Fig. 1: RSMVA Basel © Valorec Services AG

The use of Endress+Hauser‘s WirelessHART portfolio enabled a quick and uncomplicated realization of the project. Despite the dense plant infrastructure (tanks and piping), wireless communication between the devices functions perfectly. Thanks to excellent co-operation between RSMVA and Endress+Hauser workers, the entire project could be finished in two weeks. The commissioning of the plant required only two days. Due to the temperature and pressure measurements made available via WirelessHART, RSMVA can monitor its DeNOx plant in Basel more exactly and maintain it more easily. The optimization of the cleansing process with respect to time and location, means considerable cost savings are to expected.

Fig. 2: Temperature transmitter with WirelessHART Adapter SWA70 installed on the heat exchanger

Moreover, a more exact monitoring of the plant reduces constraints on the process, so that the emission values are not merely reached, but at the moment, at approx. 50 mg, are significant better than those required by law.

Endress+Hauser’s WirelessHART Portfolio Endress+Hauser WirelessHART portfolio comprises a central access point for wireless transmissions, the so-called gateway, and the adapters. The latter acquire the measured values from the measuring instrument and transmit them to the gateway. An adapter can be mounted on any field instrument that provides its data via a HART or 4 – 20 mA interface. The battery integrated into the adapter can also supply device power, so that a cable is not necessary. Depending upon how often data is to be transmitted and which device is connected, the battery can have a service life of several years before it needs to be exchanged. Where necessary, the exchange can be made in an explosion hazardous area (Zone 1). Every adapter can transmit and receive data, i.e. also relay data from other participants in the network. Obstacles can be surmounted or avoided by using adapters as repeaters. This allows a meshed network to be built, ensuring stable data transmission. A network manager in the gateway organizes the communication path, i.e. through which participants in the network the data should be transmitted. It recognizes changes in the network and if necessary, automatically adjusts the communication path. To support this, additional adapter information is continually evaluated, e.g. service life of the battery or signal strength.

Fig. 3: Visualization of the DeNOx plant in the ABB control system

The web server of the gateway allows quick access to network information via a web browser. The web interface is also used to configure the gateway and to map data in readiness for external access.

Fig. 5: WirelessHART Adapter SWA70

Fig. 4: Schematic diagram of the WirelessHART installation in the DeNOx plant. Through the use of repeaters and additional pressure measurements in the higher stories, a three-dimensional wireless network is created. december 2013 | Automation INSIGHT! | 49

Wireless and Industrial Communications

Yokogawa to Provide New ISA100 WirelessTM Module with Built-in Antenna

Wireless and Industrial Communications

Main Specifications Item Wireless configuration

First licensing contract concluded with New Cosmos Electric Yokogawa Electric Corporation announces that in December it will begin providing sensor manufacturers a new wireless communications module with a built-in antenna. This new module is intended for use in wireless sensors, and will be provided to companies that develop and manufacture these products. Yokogawa has already concluded a contract to license the use of this wireless technology to New Cosmos Electric Co., Ltd., a gas detector manufacturer. It is expected that this module will drastically reduce the amount of time required to develop ISA100.11a*1 compliant wireless sensors.

Development Background

Yokogawa advocates the Wireless Anywhere concept for the plant-wide use of wireless communications technology and is working hard to promote the use of ISA100 WirelessTM*2 communications technology solutions. As part of this strategy, we have developed this module. In plants, various sensors are used to measure temperature, pressure, level, gas concentration, vibration, and so on. To develop wireless sensors for such applications, not only do manufacturers need to acquire the necessary wireless technologies, they must also comply with the radio regulations and explosion protection standards in each country. Based on the various technologies and knowledge that it has acquired through the development of field wireless systems, Yokogawa has developed a wireless communications module with a built-in antenna that can help sensor manufacturers significantly shorten the time needed for developing wireless sensor products. New Cosmos Electric, a company with a solid track record in providing gas detection solutions to the manufacturing industry, is planning to develop a wireless gas detector. In view of its high reliability, flexible applicability, and network expandability, the company has decided on an ISA100 Wireless solution for this field wireless 50 | Automation INSIGHT! | decEMBER 2013

product. Accordingly, Yokogawa will provide this module and the technology assistance needed to develop a wireless gas detector.

Advantages of Using This Module

Sensor interface

1. Speeds up wireless sensor development

This module is comprised of an antenna and associated wireless communications circuitry. By installing this module on a sensor that includes components such as an interface circuit and power supply, a sensor manufacturer can greatly speed up the process of developing an ISA100 Wireless sensor.

2. Complies with radio regulations and explosion protection standards

Based on its wealth of technologies and expertise in the development of field wireless devices, Yokogawa has been able to design a module that complies with over 100 countries’ radio regulations as well as all the major explosion protection standards. Sensor manufacturers thus do not need to certify that their sensors meet such regulations and standards, drastically shortening development time.

3. Compact and lightweight

Including the built-in antenna, this module is only 116 mm long and 23 mm in diameter, and weighs just 100 grams. This allows the development of compact and lightweight field wireless sensors.

Major Target Markets Sensor manufacturers who are developing field wireless devices for use by the oil, petrochemical, chemical, pulp and paper, pharmaceutical, food, iron and steel, and other industries.

Operational configuration

Specifications Communications protocol

ISA100.11a (IEEE802.15.4 compliant)

Frequency range

2,400 MHz to 2483.5 MHz (max. 15 channels)

Output

Max. +12 dBm (+2 dBi omni-directional antenna)

Communications distance

Max. 1,600 m (line of sight)

Connection speed

9,600 bps to 57,600 bps (RS485 compliant)

Cable length

Max. 20 m

Input voltage

3.3 V±10%

Enclosure class

IP66/67, NEMA4x

Operating temperature

Standard model: –40°C to +85°C Intrinsic safety and explosion protection model: –40°C to +70°C

Note: Specifications may differ depending on when the module is provided.

Yokogawa’s Approach to Field Wireless Communications

About New Cosmos Electric Co., Ltd.

Field wireless systems utilize wireless communications networks to link a plant’s field devices with its control systems. Yokogawa designs these networks to comply with the ISA100.11a standard. In addition to being highly reliable, suited for a wide range of applications, and expandable, they are compatible with wired communications standards such as FOUNDATION™ fieldbus, HART®, and PROFIBUS. The International Electrotechnical Commission (IEC) is currently considering the adoption of the IEC62734 standard, which is based on ISA100.11a.

New Cosmos Electric produces products in a variety of related fields based on its unique gas sensor technologies. These products include industrial gas detection systems, portable gas detectors, residential gas alarms, odor sensors, and products that incorporate odor sensors.

Yokogawa released the world’s first ISA100.11a compliant field wireless system devices and wireless pressure and temperature transmitters in July 2010. In addition to enabling sophisticated control techniques in continuous processes, this gave customers a wider range of devices to choose from. In July 2012, Yokogawa released a reliable, large-scale field wireless system for use in plants and is now expanding the range of suitable monitoring and control applications for wireless technologies and devices. In line with the Wireless Anywhere concept, Yokogawa will continue to expand its lineup of ISA100 Wireless solutions and provide either free of charge or on a license basis various fundamental technologies in modular form.

*1 ISA100.11a A communications standard from the International Society of Automation (ISA) that is used by field wireless systems *2 ISA100 Wireless A technology that is based on the ISA100.11a standard. It includes ISA100.11a-2011 communications, an application layer with process control industry standard objects, device descriptions and capabilities, a gateway interface, infrared provisioning, and a backbone router. The names of companies, products, and brands in this text are registered trademarks or trademarks of the respective holders.

december 2013 | Automation INSIGHT! | 51

YOKOGAWA YTA SERIES “NEW ERA OF SMART TEMPERATURE MEASUREMENT” YOKOGAWA’S PROVIDES IMPROVED ACCURACY AND ENHANCED RELIABILITY COUPLED WITH EASE OF OPERATION & MAINTENANCE

YTA Features

Opportunity Identification Services to Maintain YOKOGAWA YTA SERIES “NEW ERA OF Operational Excellence Over theMEASUREMENT” Entire Plant Lifecycle SMART TEMPERATURE Author: TAKASHI NAITO (Yokogawa Middle East and Africa B.S.C. (c), Business Development Department)

Implementation of continuous improvement programs is one of the most effective approaches to maintain operational excellence over the entire plant lifecycle. The programs consist of three steps: 1. opportunity identification 2. solution implementation, 3. maintaining of improved performance.

2. Improvement Leader Development Service

Another key to enhance the efficiency of opportunity YOKOGAWA’S identification PROVIDES is to develop leaders who will engage in continuous improvement programs. Such leaders will find the improvement IMPROVED ACCURACY ENHANCED items and take AND initiatives to promote the programs. It is expected that the leader has enough experience of improvement activities. Nevertheless, it takes time to develop such leaders through actual RELIABILITY COUPLED WITH EASE OF improvement activities in the operating plant. Yokogawa has In the first stepOPERATION of a program, the potential provided a unique training program especially for improvement & MAINTENANCE areas of improvement are identified and analyzed leader development. In the training program, participants can learn in terms of prioritization. Yokogawa has provided Opportunity Identification Services TM to enable manufacturers to do this step more efficiently and systematically. The following two services are the major components of Opportunity Identification Services.

the methodology of improvement procedures, put it into action immediately in a virtual environment consisting of a dynamic process simulator and a process control systemto have a successful experience in the improvement activity. For instance, the typical questions are answered through the practical exercises in the alarm rationalization course. How to evaluate the performance of alarm system? How to manage the chattering alarms? How to design the alarm priority? When the course is completed, the participants will 1. Effectiveness Analysis Reporting Service be motivated to start the learnt procedures in their plants. Two • Guaranteed Stability for 5 years without calibration more courses are available for automation of procedural operation Since plant operations are conducted by and regulatory control stabilization. • Dual compartment housing for increased reliability operators via process control system, the • Best in Class Accuracy of 0.02% information on the system can give us a clue for • Dual sensor option for differential temperature or single opportunity identification. The data is collected sensor with backup on the system automatically and summarized as Effectiveness Indicesfor the following categories: • Transmitter sensor compensation increases accuracy 1. automatic control, • TUV Certified for use in SIL2 & SIL3 safety applications 2. alarm, • Information rich display for easier configuration and 3. manual intervention, operation 4. human machine interface, 5. management of change, • Large terminals and improved wire routing for easier 6. RASIS (Reliability Availability Serviceability installation Integrity Security).

Fullless e Wirption e! o labl i ava

YTA Features

• Guaranteed Stability for 5 years without calibration • Dual compartment housing for increased reliability • Best in Class Accuracy of 0.02% • Dual sensor option for differential temperature or single sensor with backup • Transmitter sensor compensation increases accuracy • TUV Certified for use in SIL2 & SIL3 safety applications • Information rich display for easier configuration and operation • Large terminals and improved wire routing for easier installation • Advanced diagnostics provide faster fault rectification • Available with 4-20mA, HART, FF and ISA100 connectivity • Accepts up to 20 sensor input types to reduce inventory costs

Fullless e Wirption e! o labl i ava

• Advanced diagnostics provide faster fault rectification The service provides a comprehensive set • Available with 4-20mA, HART, FF and ISA100 connectivity of reports showing the Effectiveness Indices in • Accepts up to 20 sensor input types to reduce inventory costs

various types of plots. To support the analysis, the average values from Yokogawa’s global database and the drill-down information (e.g. breakdown, For more information please contact us on +973 1735 8100 bad actor list) are also available in the report. or email at yma@bh.yokogawa.com The information about proper solutions to the identified areas of improvement is provided for the Though improvement activities tend to be focused on next step of continuous improvement programs. the solution implementation part, the preparatory part is also The strategy and plan of solution implementation important to set the proper direction of activities and train the can be discussed with a Yokogawa consultant. members for leading a team. This article introduced two approaches of Opportunity Identification Services.

For more information please contact us on +973 1735 8100 or email at yma@bh.yokogawa.com

www.yokogawa.com/bh

functional safety and sis

Functional Safety and SIS

Operations Monitoring

Key to Improving Plant Performance, Reliability and Safety Author: Chris Stearns, Honeywell Process Solutions Many automated industrial plants have now implemented some type of operations monitoring program. However, the effectiveness of these programs—the next logical step after alarm management—can be limited by the use of ad-hoc or standalone tools such as spreadsheet applications to evaluate process variables against operating limits, conduct plant data analysis and perform stewardship reporting. The following article describes the implementation of effective operations monitoring solutions for process industry facilities. New technology is available for systematically monitoring plant performance data and analyzing deviations from operating plans. Becoming aware and reporting to the right people is key to achieving operational excellence.

Today’s Operational Challenges For process plant owners, it’s important to support control engineers, optimization engineers and operators who are implementing best practices for operational excellence aimed at meeting the plant’s business and safety goals. Personnel must monitor a wide range of measurements and key performance indicators (KPIs) from plant and equipment at a production site, as well as maintain the required values of variables to meet operating objectives such as maximum yield, utmost efficiency and minimum emissions (See Fig. 1).

Understanding operating limits An operating envelope is a collection of constraints, boundaries and operating limits in an industrial facility that, when exceeded, put the integrity of assets at risk. These limits are typically based on combinations of factors such as process unit capacity, equipment constraints and safety concerns. They can also be implemented for alarm systems and operating targets. According to the Abnormal Situation Management Consortium® (ASM®), ensuring operations remain within correct limits is central 54 | Automation INSIGHT! | decEMBER 2013

Need to Optimize Performance Plant owners and operators are under continual pressure to optimize their facilities and processes. This means achieving greater productivity more efficiently with fewer resources. Data about plant performance is key to making smart operational decisions, but in most cases, operators have access only to piecemeal information about their units and processes—examining performance often in a vacuum.

Importance of alarm rationalization

Figure 1. For process plants, best practice operation means ensuring maximum yield, utmost efficiency and minimum emissions.

to avoiding many of the root causes of abnormal situations. To maximize the life of an asset in an industrial facility, it must be operated according to design parameters and not simply within process safety limits. That means extending operating strategies beyond operator visibility to the entire operations team and all those interacting with the process. Without a comprehensive limit management solution, operators lack the insight needed to run plants within operating envelope boundaries.

Process industry facilities typically devote considerable resources to rationalizing their alarm systems so operators can effectively manage the process and not just respond to alarms throughout the shift. Alarm rationalization involves reconciling individual alarms against the principles and requirements of the alarm philosophy. It is important that the relevant data for each alarm is documented to support the other stages of the lifecycle. This includes the alarm description, settings, causes of an alarm, consequence of no action, required operator action, response time, consequence rating, and so on. A properly designed and well functioning alarm system is imperative to operational excellence initiatives, but it is not enough to simply operate within alarm boundaries. Operations managers need to know if units are running in a range that will assure production plans are met while staying within limits, which include (but are not limited to) equipment constraints, economic targets, environmental standards, safety system regulations and advanced process control strategies (See Fig. 2).

Operations monitoring is meant to address questions such as: • Are operating plans being met? • What are the safety, process, design, reliability and environmental limits, and are these limits in effect consistently? • If plans or limits are being violated, why? • How can process performance and unit reliability be improved? In many cases, operations monitoring programs make use of ad-hoc or standalone tools, such as spreadsheet applications or a combination of e-mail and printed reports, to evaluate process variables against operating limits, conduct plant data analysis and perform stewardship reporting. Because personal spreadsheets are generally not subject to the same rigid control standards as other IT applications, errors and omissions can occur, impacting the accuracy of information used to develop planning targets and identify environmental constraints. Without a central data repository, different individuals may apply different data as the basis for reporting and decisions. Spreadsheets may also limit access to daily operating information for the rest of the organization. In addition, ad-hoc tools linked to plant historians can be a headache for IT to support. Spreadsheets are often inconsistently applied and difficult to keep up to date when the process or historian changes, or when their owner moves to a different job or site. Plus, they may not be well suited to following through on problems once identified. Although an historian itself captures a wealth of vital data, plant optimization efforts will struggle without feedback from operations to put information regarding process limits, excursions, upsets and other activity in proper context.

Industrial sites typically employ multiple types of process control applications, each of which can be used to independently enter and control respective targets, constraints or limits. Although these applications may relate to the same process measurements, the limits they use are sometimes inconsistent or conflicting. This situation can result in inefficient operation, costly process upsets and unplanned shutdowns. Various groups within the plant are responsible for maintaining safe operating limit information. As these variables are often system configuration parameters entered by humans, there is the possibility values may fall outside of the safety and compliance envelope. Additionally, some processes have dynamic safe operating limits that are continually changing, which is challenging for plant operators to manage. As these limits are adjusted for safety, reliability and optimization reasons, staff across the facility must have current and updated exceedance reporting to effectively manage site performance.

the tools for an operations department to establish and manage engineering limits and constraints, monitor performance to plan and limits, and to follow-up on performance problems.

Figure 2. A properly designed and well-functioning alarm system is imperative to operational excellence initiatives.

Value of operations monitoring Many automated industrial plants have now implemented some type of operations monitoring program. These programs provide

Typical Industry Applications Operations monitoring has evolved into an ongoing process employing advanced applications to proactively leverage fewer experts—using better technology—to focus on overall performance, often with the help of external vendors and december 2013 | Automation INSIGHT! | 55

Functional Safety and SIS

partners. Today’s virtual environment allows the enterprise to monitor each plant in real-time to achieve continuous learning and sustained improvement.

overall operations management portfolio. Too often, however, this technology required users to accommodate a large hardware footprint, complex and costly server infrastructure and licensing, and extensive programming effort. This situation drove up the cost of operations monitoring programs and forced plant engineers to rely on less complicated “homegrown” monitoring techniques.

How the technology is used In a typical process plant, operations monitoring can be used to monitor measured and calculated process tags against operating, safety and corrosion limits, as well as other indications of reliability. Such engineering limits typically don’t change often and may have safety, environmental, or maintenance implications if they are violated. Another common use for operations monitoring is to evaluate process data and KPIs against planning limits. Planners frequently adjust operating ranges when production strategies, product grades, or feeds change in a process unit. These limits usually change frequently and can have economic implications. Violating planning limits can mean reduced product quality, the wrong production rate, missed shipments to customers, etc. (See Fig. 3).

Alternative to spreadsheets

Figure 3. Operations monitoring is commonly used to evaluate process data and KPIs against planning limits.

Operations monitoring helps automate tracking actual process performance every shift. Many plants benefit from improving how routine issues are handled, before they grow into problems. For example: • A de-salter in a crude unit is designed to operate at up to 350 degrees, but the corrosion rate increases noticeably when operated above 300 degrees. Systematically tracking excursions above 300 degrees and fixing the root causes of the deviations will extend the life of the equipment. • A reboiler gradually fouls, reducing heat transfer and eventually limiting production. An anti-foulant is available but expensive, and the ideal injection rate is poorly understood. Monitoring the energy efficiency can help determine when an operator should look at the injection rate. • A purge rate needs to be temporarily increased to remove impurities from a column. Monitoring the purge rate and the yield helps ensure the purge valve will be reset at the right time, which will prevent an undesirable loss of production.

Latest Monitoring Solutions Plant operations departments are re-thinking their approach to operational excellence in order to realize the maximum benefit from ongoing technology developments. Instead of simply managing the effects of operating outside established boundaries, they are seeking to expose the operating envelope to all appropriate plant stakeholders and ensure it is well understood across operations and related organizations. Technology providers have historically offered operations monitoring applications as part of an 56 | Automation INSIGHT! | decEMBER 2013

The current breed of operations monitoring solutions helps industrial organizations transition from labor-intensive, legacy plant performance spreadsheets to an automated and standardized system for facility-wide data collection, analysis, and reporting. This allows the enterprise to move beyond disjointed spreadsheets and difficult scripting languages, non-standard and inefficient processes, and inconsistent calculations requiring significant manual input. New software tools are intended to systematically monitor process plant performance data and summarize deviations from the operating plan. These tools are well suited for tracking operating performance against targets and highlighting problem areas. They are designed to fit into existing work processes and help operations teams institutionalize those procedures.

Operations monitoring to enable better decision-making is a growing necessity based on current plant operational demands. Even experienced operators may not know the best operating range for throughput or may fail to realize the consequences of operating outside of targets. Furthermore, operations monitoring helps industrial facilities move to the next level of operational excellence by leveraging the inherent benefits of alarm management initiatives. Operations monitoring benefits come from a variety of sources, including: • Reduced number and severity of incidents • Reduced operating and maintenance costs through increased asset reliability • Better safety and environmental compliance • Increased operating margins through better fidelity to the operating plan

An effective operations monitoring solution delivers these benefits by supporting a structured, Hima - Quarter Page.pdf 1 11/4/13 11:55 AM systematic monitoring program. Engineers can

Integrated with plant data sources Today’s operations monitoring infrastructure may reside at level 3 or 4 of the plant network hierarchy, utilizing industry-standard OPC data access to establish connections for retrieving real-time data from historians and various other data sources. Monitoring solutions employing browser-based displays can provide plant-wide access to monitoring results (See Fig. 4).

End User Benefits

HIMA solutions provide maximum safety and process availabiliy

A typical process plant might use an operations monitoring tool as follows: • Engineers, head operators, and other staff meet every few weeks or months to review reports and comments entered by operators when considering updates to safe operating limits throughout the plant. • Process data are monitored every few minutes. Any deviations outside operating limits are recorded. • Operators enter comments about important deviations by the end of the shift. • Monthly stewardship reports provide information such as the total number of deviations, the top ten tags in each unit with the most problems, and the top reasons why deviations occurred.

+971 4 883 4489 +971 4 883 4778 december 2013 | Automation INSIGHT! | 57 info@hima.ae

www.hima.ae

Functional Safety and SIS

Figure 4. Operations monitoring tools can be used to systematically monitor process plant performance and summarizes deviations from the operating plan.

ENSURING SAFE OPERATION AND ENGINEERING ADVANTAGE FOR THE WORLDS ENERGY CUSTOMERS HIGH INTEGRITY SOLENOID VALVES ading try le Indus e Friction Forc io (FFR) Ra t

YOU CAN SEE OUR THINKING

e 10 year servic to s interval (6 year3) maintain SIL

ENGINEERING ADVANTAGE

ions inside Cable terminat tional Ex di ad No coil required ns io at termin

Functional Safety and SIS

utilize the latest software technology to monitor process values and record anything outside of the normal range, as well as scan, filter and consider these deviations in context. Operators and engineers can then assign reasons and comments to the deviations, while managers assess actual performance and set priorities based on associated reports. In addition, IT professionals can take advantage of operations monitoring as part of an integrated plant information system allowing them to minimize administration costs, access process data from plant historians, and reduce capital and implementation costs with a common architecture across business applications.

Conclusion Improving operational performance and reliability requires a team effort by operators, engineers, and various other specialists within the plant. These people will benefit from operations monitoring solutions that build on alarm management efforts and improve their ability to monitor the performance of processes and operating assets to make profitable operational decisions for both the short and long term.

See more of our thinking and 58 | Automation INSIGHT! | decEMBER 2013 the advantages it delivers SEE ENGINEERING ADVANTAGE Scan with a QR code reader

energy@norgren.com www.norgren.com

How to Implement Functional Safety, IEC 61511 Author: Heidi Fuglum, Deployment Manager, ABB

What is safety? All aspects of safety are important, but safety can mean different things to different people. Some care is needed to understand the context and relationships, and to understand what is important to others. When we discuss safety there are a number of different phrases in use, within the oil and gas industry, and there are also areas of overlap. Depending on the company and industry this may vary a little, but the following phrases are typically encountered:

Figure 1: Overview of safety areas december 2013 | Automation INSIGHT! | 59

Functional Safety and SIS

HSE/OHS – Health, Safety and Environment or Occupational Health and Safety Occupational or Personal Safety – is concerned with the wellbeing of the individual in the workplace, primarily through the application of training and simple rules, procedures and protective measures. It doesn’t matters whether the workplace is an office, a manufacturing plant or an offshore platform. We often refer to this area of safety as the “management of slips, trips and falls”.

Process safety

Functional Safety and SIS

Human Factors and Safety Culture

Process Safety focuses on preventing fires, explosions and accidental releases of oil, gas and processes and facilities dealing with hazardous materials such as refineries, and oil and gas (onshore and offshore) production installations. Therefore process safety is very focused on maintaining containment. The term is used internationally, but there may be different words depending on industry and geographical location.

Hazard and Risk

When it comes to the management of major accident risk, the oil, gas and petrochemical industry has certain special factors. The prevention of fires, explosions and accidental releases of hydrocarbons is clearly very important. However, there are also other major risk factors present in offshore operations due to the special nature of the activities and its environment. These risk factors are typically associated with the weather, the sea conditions, the movement of materials and personnel and the lifting of heavy loads.

Hazards have the potential to cause us harm. This harm can occur through direct physical, injury ‐ to us or others. It could also occur as an illness, either acute or chronic. Harm could also be caused indirectly, by damage to property, structure and machines, which in turn could then harm us.

Product Safety

Product safety – product safety aims to ensure that any manufactured item or system is safe for its intended use. Design and manufacturing must therefore usually follow established rules and standards.

Functional safety

Functional Safety refers to the part of the overall safety that depends on a system or equipment operating correctly in response to its inputs. More specifically, the term is being used in relation to the application of the IEC 61508 Standard, covering the functional safety of electrical, electronic and programmable electronic safety‐ related systems. Even more specifically, in the context of the oil and gas industries, the term is referring to the application of IEC 61511, covering safety instrumented systems for the process industry sector. We are therefore referring to compliance with the safety standard that covers the specification, design, installation, testing and maintenance of safety instrumented systems that must reliably respond to plant conditions that may be hazardous and which must generate correct outputs to prevent or mitigate the consequences.

60 | Automation INSIGHT! | decEMBER 2013

What is a safety system?

Human error is involved in the majority of incidents and accidents. Even if not directly involved in the immediate incident, human error may well be present at some point in the event sequence – perhaps in the design, the manufacturing, or maintenance processes. The study of human factors and its relationship with safety processes, safety management and safety culture is therefore an important and wide ranging topic.

In order to discuss functional safety management in more depth, we must first make sure we understand one or two fundamental definitions, Hazard and Risk

Risk is the combination of the Severity of the harm and the Likelihood that that event might happen.

A Safety Instrumented System (SIS) is a collection of sensors, controllers and actuators. It executes one or more Safety Instrumented Functions (SIFs) that are implemented for a common purpose. The Safety Instrumented System (SIS) will together with other protection layers reduce the risk that a process may become hazardous to a tolerable level. The SIS does this by decreasing the frequency of unwanted accidents. SIS senses hazardous conditions and then takes action to move the process to a safer state, preventing an unwanted event from occurring.

What is the purpose of a safety system? The purpose of a safety system is to reduce the risk and to keep the plant, people and business safe The amount of risk reduction that an SIS can provide is represented by its Safety Integrity Level (SIL). • SIL is defined as a range of Probability of Failure on Demand (PFD), • Safe Failure Fraction (SFF) and • Avoidance of Systematic failures which can be represented as the Systematic Capability for the each of the elements in the SIS.

Severity is a measure of the degree or extent of the harm. This could range from a minor injury to a serious injury or even a fatality. In the extreme, the outcome of a major accident could result the loss of many lives, perhaps including innocent people who were not immediately involved in the activity or operation. The higher the severity, the more protective measures will be needed. Likelihood tells us how frequently the event might happen. The higher the likelihood, the more protective measures will be needed.

Why safety system? When the risk assessment concludes that existing risk reduction is not enough to reduce the risk to an acceptable level a Safety Instrumented System [SIS ‐ 61511 terminologies] is very commonly used. This is popular because it is highly configurable and gives good risk reduction for the money.

So a safety system as we know it from oil & gas industry is in many cases a dormant system safeguarding the process control system. The control loop maintains a process variable within prescribed limits, while the SIS monitors a process variable and take action only when required. The objective of IEC 61508 is to design a “safe safety system” A safe safety system is tolerant to internal failure AND can execute the safety function OR it can’t carry out the safety function but it will notify operator via alarm.

Figure 2: Safety Instrumented Function (SIF)

Safety Lifecycle

Operation and maintenance

The Analysis Phase ‐ The safety lifecycle start at the concept phase and analyze the situation and document the safety requirements which gives an acceptable risk level

Then the last phases are the Operation and maintenance. The operation and maintenance need to be done according to procedures, documenting the actual behavior of both the safety system and the plant demands for safety, to correct any deviation so that performance standards are maintained throughout the systems lifecycle.

Design and Installation/Realization Phase ‐ Then the requirements are translated into different risk reduction functions including a safety instrumented system with documented design, using appropriate hardware and software and design methods. The system must be evaluated and validated against the required integrity and functionality specification.

december 2013 | Automation INSIGHT! | 61

Functional Safety and SIS

Functional Safety and SIS The Functional Requirements is a description of what the Safety Instrumented Function (SIF) shall do. The Integrity Requirements is how well the SIF shall work – the level of confidence. How reliable the SIF must perform its duty. Under is a list of some of the important functional requirements of the SRS. The complete list is found in IEC 61511 – part 1, Clause 10 • • • • • • • • • • • • •

Description of the SIF Definition of the safe state Process inputs and their trip points Process parameters normal operating range Process outputs and their actions Relationship between inputs and outputs Selection of energize‐to‐trip and reenergize‐to‐trip Response time requirement Operator interface requirement Considerations for manual shutdown, and Considerations for bypass and override Action on loss of power to the SIS Response time requirements for the SIS to bring the process to a safe state • Reset functions

In order to make sure we are doing the right things and also doing the things right; phase 9‐11 go from concept phase to decommissioning. The safety lifecycle is also a good way to ensure that all the organizations involved understand their role and responsibility and pass information and documentation between involved parties

How to know what we need? Through the process hazard analysis most of the requirement for functionality and safety integrity is determined. This task is done by the end user / owner of the plant since the they understand the hazards of their process and they are experts on their own production process. There may be 3rd party experts or facilitators to join in the analysis phase. The objective of the Hazard and risk analysis is to identify the process hazards, estimate their risk (consequence/severity and likelihood) and decide if the risk is tolerable. The result of the process hazard and risk assessment shall result in a verbal description of each safety loop/safety function to protect the plant including the following information. Each safety loop should protect for a specific hazard: 62 | Automation INSIGHT! | decEMBER 2013

• A description of each identified hazardous event and the factors that contribute to it • A description of the consequences and likelihood of the event • Considerations of conditions and modes • The determination of requirements for additional risk reduction • A description of the measures taken to reduce or remove hazards and risk. • Allocation of the safety functions to layer of protection • Identification of those Safety functions applied as safety instrumented function

Safety Requirement Specification (SRS) The result of the hazard and risk assessment is the input to the Safety Requirement Specification. Definition of Safety Requirement Specification is defined in IEC 61511 – part 1, 3.2.78 “Specification that contains all the requirements of the safety instrumented functions that have to be performed by the safety instrumented systems” The Objective of the Safety Requirement Specification is to specify all requirements of Safety Instrumented System (SIS) needed for detailed engineering and process safety information purposes. The requirement is grouped into functional and integrity requirement.

The SRS should also contain these integrity requirements • The required SIL for each SIF • Requirements for diagnostics to achieve the required SIL Requirement for maintenance and testing to achieve the required SIL • Reliability requirements if spurious trips may be hazardous

Documentation Since we work in lifecycle phases and we need to pass on information between different engineering disciplines it is important with documentation. Also the traceability and the need to always have up to date information / version control is important. Anything that can be stored and which can be properly identified can be used as documentation. Typical documentations which are central for safety • Hazop reports • Safety Requirement Specification • Functional Design Specification/Safety Analysis Report • Safety plan/Safety Lifecycle Management Plan • Test documents (Specifications & Records) • Competence (Role descriptions & Competence requirements for each role) • SIL Compliance report / SIL verification report

Reduce costs and improve quality of calibration Beamex documenting calibrators and software form an automated paperless calibration system.

Responsibilities The owner of the plant is responsible for safety, irrespectively who has done the design of the safety system. The owner need to make sure the different vendors follow the regulations and the chosen architecture and selected components meets the requirement. The end‐user often doesn’t have capabilities to verify all products used for the safety functions. By using certifies product according to IEC 61508 that means that a 3rd party (often TUV) has verified that the product comply to standard. A certified product addresses Electrical safety, environmental safety, EMC, User documentation and reliability analysis additional to functional safety according to IEC 61508.

Beamex ICS is not just a product or even a set of products and services – it is a new process of performing and managing calibrations in december 2013 | Automation www.beamex.com INSIGHT! | 63 a way that provides efﬁciency and quality info@beamex.com improvements as well as cost-savings.

Functional Safety and SIS

Competence requirement and roles in a safety project The competence of people involved in safety projects is normative according to IEC 61511 (part 1, Clause 5.2.) In the planning phase of the safety system it is required to identify the competence needed, what is available in‐house and what needs to be added. There is a need for role descriptions and competence requirements for each role including requirement for education, training or experience. Competency is especially required with regards to functional safety and the technology used.

Functional Safety and SIS

According to IEC 61511, a minimum, the following items should be addressed when considering the competence of persons, departments, organizations or other units involved in safety life‐ cycle activities: • engineering knowledge, • training • experience appropriate to the process application Example of roles in a project with are: • Project Manager, • Safety Lead Engineer/Functional Safety Manager • Safety Engineers • Safety Assessor Even though the Project Manger does not always work with technical issues it is important that the management have an understanding for Functional Safety Management.

Conclusion – Functional Safety To keep the plant safe it is not enough to use reliable hardware. We need to look at • What is the risk? And how can it be reduced? • How to avoid failures? • The entire lifecycle to be considered • Work processes need to be established for each phase in the lifecycle Importance of Competence should not be ignored SIL is applicable for a function not for a component alone References • White paper, Functional Safety for End‐Users and Systems Integrators, (2006) T. Vande Capelle, Dr M.J M Houtermans • WIN – WIN a MANAGERS GUIDE to FUNCTIONAL SAFETY , Curt Miller • IEC 61508 Functional safety of electrical/electronic/programmable electronic safety‐related systems IEC 61511Functional safety – Safety instrumented systems for the process industry sector 64 | Automation INSIGHT! | decEMBER 2013

Using Wireless Communication in Safety Instrumented Systems Author: Edward M. Marszal, President,

Kenexis

Wireless communication systems are becoming more and more widely utilized in the process industries. Initial shortcomings in these systems, whether real or only perceived, are being addressed, and early skepticism is quickly being replaced with enthusiastic support. Equipment vendors are also spending a lot of time and effort in enhancing designs, using techniques such as smart meshes, to increase the overall availability of these communication systems to the point where their reliability is approach, and in some cases, surpassing the reliability of wired systems. Even with the improvements in availability and generally increased support by instrumentation and control engineers, one area where adoption is slow to non-existent is safety instrumented systems. While there are a number of very good

opportunities for use of wireless SIS (such as remote tank farm shutoffs), wireless is almost never adopted for SIS. In fact, most practitioners believe that there are strict standards based rules preventing the use of wireless systems for SIS. While standards bodies such as the ISA 84 committee have developed technical reports regarding the use of BUS systems, and wireless communications for SIS, there technical reports are non-normative, and simply to be considered guidance. Only the requirements in the actual standards, specifically IEC 61508 in this case, are required to be adhered to. Contrary to most discussion, the core standard (IEC 61508) is not violently against wireless december 2013 | Automation INSIGHT! | 65

Functional Safety and SIS communications. The notion that wireless is forbidden was never precisely true. In fact, it was only generally assumed based on most people’s gut reaction to the use of (at this point in time) unproven wireless systems in critical safety applications. Most of the safety communication protocols that are used by equipment vendors are “medium agnostic” meaning that it really doesn’t matter what the signal travels on because all of the safety attributes are built in to the sending mechanism and the receiving mechanism. The sending and receiving equipment are equipment with elaborate and comprehensive diagnostics which ensure that communication is progressing safely, and if not, detect that fact and take appropriate actions. Failures of wireless systems are virtually 100% detectable in a millisecond time frame, as such, safety is not an issue at all.

Kenexis Global Leaders in Technical Safety

There are two real reasons why people don’t currently use wireless for safety (much). 1. No vendor (that I am aware of) has engineered and certified (by a third party, to the IEC 61508 standard) a wireless solution. General purpose wireless solutions are not designed in accordance with IEC 61508-2, 3, and as such are not allowed in safety applications. A safety “certified” set of equipment is not available to my knowledge. You can’t just put a cisco wireless router from Best Buy in the middle of a safety loop, it would need to come from the vendor of a complete solution. 2. Nuisance trips. While failures are very detectable, they generally need to result in a vote to trip. At this point in time, wireless failures are so frequent that the impact of nuisance shutdowns precludes the use of wireless systems in most SIS applications.

FGS Mapping - SIL Calculations HAZOP/LOPA - QRA Free download of the Kenexis Performance Based FGS 66 | Automation INSIGHT! | decEMBER 2013 Engineering Handbook at www.kenexis.com

I expect that once end users get comfortable that nuisance trips rates can be made low with a reliability wireless communication system design, and equipment vendors make certified solutions available, wireless communications in SIS will become very prevalent.

asset performance and productivity enhancements

Asset Performance and Productivity enhancements

New Online Motor Stator Insulation Monitor (MSIM) for 3500 System Author: C. David Whitefield, P.E. Bently Nevada Principal Engineer dave.whitefield@ge.com Many of our customers employ medium and large AC motors (such as the representative example in Figure 1) as prime movers for their process machinery, driving large compressors, pumps, blowers and fans. Traditionally, many of these motors have been mechanically protected and managed using Bently Nevada 3500 vibration and condition monitoring systems. The majority of motors in this class employ fluid film bearings.

The Problem The 3500 System is effective for vibration monitoring of motor rotor and bearing faults, but another common problem with motors is the degradation of stator winding insulation. Stator problems, combined with bearing problems (detected by vibration), constitute over 75% of motor failures. The need to address the stator failure mode is obvious, yet there are few, if any online systems which meet that need. Existing condition monitoring techniques for this class of motors fall into one of two categories â&#x20AC;&#x201C; offline or online monitoring.

Offline Monitoring This type of testing is done with the motor shut down, cooled down, and de-terminated, using portable test equipment. Tests in this category include the following examples: â&#x20AC;˘ Capacitance and dissipation factor (C & DF) testing, which are both conducted at ambient temperature. 68 | Automation INSIGHT! | decEMBER 2013

Figure 1: GE Pegasus** MHV Medium Voltage AC Induction Motor [Reference 1]

december 2013 | Automation INSIGHT! | 69

Asset Performance and Productivity enhancements • Megohmmeter (“megger”) for Insulation Resistance (IR) and polarization Index (PI), AC and DC high-potential (“hi-pot”), Partial Discharge (PD), Power Factor or Dissipation Factor (tip-up) and other electrical tests designed to assess the condition of the stator insulation system. • Partial Discharge Analysis: This measurement looks for indications of tiny arcs that occur within voids and gaps in the winding insulation as it deteriorates over time. Both permanentlyinstalled and portable versions of PD instruments are used. Other techniques can be used to complement the above tests for more effective diagnostics and health assessment.

Online Monitoring This type of monitoring is done with the motor energized and running, usually at a significant fraction of full load. Online monitoring can be performed with permanently installed instrumentation, or with portable test equipment. • Ground/phase fault relays: These are classic machine protection relays, which were originally electromechanical devices, and evolved into solid-state analog, then digital devices. Protective relays are permanently installed to provide realtime automatic protective measures for detected electrical faults. Modern digital relays can also provide some condition monitoring data via digital network communications. • Partial Discharge Analysis (PDA): This measurement looks for indications of tiny arcs that occur within voids and gaps in the winding insulation as it deteriorates over time. Both permanentlyinstalled and portable versions of PD instruments are used. • Temperature, moisture and other parameters can also be continuously monitored.

Tradeoffs Offline testing is time consuming, relatively expensive, and requires the process equipment to be removed from service while the tests are conducted. For these reasons, tests are performed 70 | Automation INSIGHT! | decEMBER 2013

Asset Performance and Productivity enhancements

infrequently, with inspection intervals of 3 to 6 years being common. This schedule means the inspection interval is the same order of magnitude as the failure interval. In addition, the offline tests are typically conducted at ambient temperatures, not at the operating temperature of the motor. Protection with ground/phase fault relays is effective in shutting the machine down after a fault occurs, but does not give adequate advance warning of insulation degradation. In some instances the stator core can be damaged by an electrical fault in spite of the shutdown capabilities of protection relay systems. Core damage results in a much more expensive repair than a basic rewind, and in some cases the motor may have to be scrapped. Partial discharge monitoring is the only currently available practical technology for online condition monitoring of stator insulation health. Feedback from our customers who have employed this technology for many years indicates that partial discharge data is difficult to interpret, and provides very little insight into, or advance warning of impending stator insulation faults.

Introducing a New Approach Bently Nevada is introducing a new approach to online stator insulation condition monitoring. This approach is based on a new sensor developed in conjunction with GE’s Global Research Center scientists. It is a complete system consisting of new transducers, a new 3500 monitor card and the services required for installation and commissioning. While it is useful as a standalone monitor, even more value can be obtained when it is connected to GE’s System 1* asset management software.

Figure 2: Permanently-installed online motor stator insulation health monitor.

Take The Lead mobility without compromise

System Description As shown in Figure 2, the new stator insulation monitoring system includes the following components for each monitored motor: • • • • • •

3 each – High Sensitivity Current Transformers (HSCTs) 3 each – HSCT interface modules 2 each – Voltage dividers (for phase reference) 2 each – Voltage divider interface modules 1 to 3 each – temperature inputs (RTD’s or thermocouples) 1 each – BN 3500 Rack and HSCT monitor card

The HSCTs, voltage dividers and all interface modules are installed in or on the motor terminal box. Field wiring directs the signalsto the 3500 monitor card.

I-safe Portable devices for hazardous operational areas 1

i.roc® Ci70 -ex: intrinsically safe pDA 1

ex-handy 08: intrinsically safe mobile phone

V100 -ex2: Fully rugged convertible tablet

Z710-ex: First Android tablet

NeC Class I, div. 1 IeCex & aTeX 5

4 5

Ck7x / CN7x: ultra-rugged mobile computers december 2013 | Automation ecom instruments (FZe) · P.O.Box 8918, Office # Z2-22 · Saif-Zone,Sharjah, Uae INSIGHT! | 71 Tel: +971 6 557 3430 email: Philip.john@ecom-ex.com

Asset Performance and Productivity enhancements

How does it work? The HSCT (Figure 3) enables measurement of very low amplitude leakage current (which leaks through degraded winding insulation). The HSCT interface module amplifies the low level signal, which is directed to the 3500 monitor card via field wiring. Voltage reference signals are similarly conditioned and directed to the 3500 monitor. Winding temperatures (from RTD’s or thermocouples) are the final inputs to the monitor card. The monitoring system conditions and processes these signals, providing access, trending and alarm- ing for values of capacitive and resistive leakage currents, Capacitance and Dissipation Factor (C & DF).

Figure 3: The HSCT is a special current transformer that is very sensitive to small values of differential current .

The offline C & DF test is used by many of our customers as a part of their medium and high voltage motor preventive maintenance programs. Our new monitoring system brings the benefits of that assessment tool to the online condition monitoring world.

Figure 4: Equivalent circuit for stator winding insulation. C = capacitance, R = resistance, V = source voltage and I = source current .

Figure 6: As the insulation system degrades, the change in capacitance and dissipation factor are indicated by the change in the phase angle between IC and IR. This example shows a case where capacitance remains unchanged, but aging increases the conduction through the insulation.

Figure 4 illustrates the basic relationship between capacitive and resistive components of the leakage current. In a new or rewound motor, the primary leakage path is capacitive, resulting in very low levels of resistive leakage current. Figure 5 shows how the Dissipation Factor describes the phase angle of the current through the stator insulation. If the insulation were a perfect dielectric, its resistance would be infinite, the angle, δ, would be zero, and dissipation factor would also be zero. Insulation systems degrade over time because of electrical, thermal and mechanical and environmental stresses. As the insulation system degrades, the resistive component increases,

Figure 7: Example photo shows the inside of a 4160 V motor termination enclosure during testing of the new HSCT sensors. The large brown CTs are for normal differential protection. The HSCTs are the thinner aluminum-covered rings to the right of the protection CTs. To the right of the HSCTs are some test instrumentation CTs that were taking additional measurements as part of the test .

72 | Automation INSIGHT! | decEMBER 2013

appearing as a larger dissipation factor, as shown in Figure 6. The leakage current measurement is temperature dependent, thus the need for the temperature inputs into the monitor.

Target Machines Our initial solution offering targets 3-phase AC induction and synchronous motors in the 1,000 to 6,000 horsepower range, operating with supply voltage in the 2.3 kV to 5 kV range. The motor must be externally wye-connected (Figure 2). We must have access to both phase and neutral leads in the terminal box, as shown in Figure 7.

Value of this method This new technology is the first com- mercially available online assessment of stator insulation system health on medium and high voltage motors via leakage current sensing. This means that you no longer have to shut your motor down for offline testing to determine if it is headed for trouble. The system allows you to realize the following advantages: • • • •

Avoid unplanned outages Do more effective maintenance planning Avoid offline monitoring downtime and associated costs Detect many problems that are not detected by existing technologies • Extend time between inspections • Reduce the cost of repair versus a protection trip, by avoiding stator core damage

System Introduction Our current development plan calls for availability in the third quarter of 2012. Please contact your local Bently Nevada sales engineer for more information. We’ll also be publishing more information on this technology in an upcoming issue of Orbit. Stay tuned for more information on motor condition monitoring!

References:

1. GE Motors Pegasus MHV Medium Voltage AC Induction Motors brochure, GEA-12310C. *Denotes a trademark of Bently Nevada, Inc., a wholly owned subsidiary of General Electric Company. Article reprinted from Orbit magazine. Copyright © 2012-2013 General Electric Company, all rights reserved. Used with permission. **Pegasus is a trademark of General Electric Company.

december 2013 | Automation INSIGHT! | 73

custody measurement

Custody Measurement

Energy Value Calculation of Partially Saturated Natural Gas on Volumetric Basis Introduction: Water may be present in natural gas in vapor, liquid or solid phase. Besides the detrimental effect of water on the gas transmission system, water reduces the calorific value of natural gas as water occupies the space in the pipeline but has no heat of combustion. Calorific value of natural gas is energy transferred in an ideal gas reaction per unit quantity of gas fuel. The energy value of natural gas may be reported on the basis of dry, saturated at base conditions, or “as delivered” of water content. It may be noted that actual condition of gas may be dry, partially saturated or saturated at flowing condition. The calorific value adjustment factor is determined based on the volume fraction of water vapor in each condition, for calculation and

reporting purpose. The calorific value used in most calculations is the gross calorific value represented as energy per unit of real gas volume.

Methods of Calorific Value Measurement:

Modern technique of calorific value calculation using gas composition provides calorific value on dry basis. This is because gas compositions are measured using gas chromatograph which generally doesn’t measure water content. Most calorimeters, measures natural gas calorific value on water saturated basis. This is because before sample gas is burned, it passes through water and gets fully saturated with water vapor. Hence though the sales gas would be dry or partially saturated with water, many gas sales agreement requires the energy value of gas to be calculated on water saturated basis. For valid comparisons of gas calorific values determined by different techniques, it is necessary to take into account:

A leading designer and manufacturer of bespoke metering, hydraulic control systems and produced water treatment solutions

Definitions of Terms:

Definition of commonly used terms in the contract and engineering are as follows The gross (superior) calorific value: is the amount of energy produced as heat per unit quantity of gas from the complete, ideal combustion of the gas at a base temperature in which all water formed by the reaction condenses to liquid. All the products of combustion are returned to the same base temperature as that of the reactants.

Total energy value of natural gas can be obtained by multiplying volume of gas by the calorific value per unit volume, both being at the same conditions of pressure, temperature and water content. When the flowing stream is water saturated, the total energy can be calculated by compensating for water vapor in the gas analysis and subsequent calorific value or by volumetrically quantifying the water vapor in the flowing stream, but not both. As H2S, when present as a contaminant, is normally removed from the natural gas stream before final use, it is usually assigned no calorific value. However H2S volume may be used while normalizing the gas components and calculating the standard volume of the natural gas. H2O volume may be used while normalizing the gas components and calculating the standard volume of the gas. However, it is not assigned any calorific value while calculating the gross calorific value of the natural gas.

Dry gas: For practical purposes, typically natural gas having moisture content not exceeding 7 lbs of water per million standard cubic feet (MMSCF) of natural gas

Sta

The various terms are interchangeably used to describe the energy value of natural gas. Unless specific definition is provided for particular application, the terms higher, upper, total and gross are synonymous with superior; the terms lower and net are synonymous with inferior.

for other contaminates like H2S, water vapor (moisture, H2O), etc.

Net (Inferior ) calorific value: The amount of energy produced as heat per unit quantity of gas by the complete combustion in air of a specified quantity of gas where in all the products of combustion are returned to base temperature as that of the reactants, all of these products (including produced water) being in the gaseous state

#C6

Sta

• the content of water vapor in the natural gas when it is metered; • the operational characteristics of the energy measurement instruments and procedure; • the degree of saturation with water vapour of the natural gas referred to in the reported calorific value.

#82

Metering Manufacturer

Produced Water Treatment

Partially saturated gas: Partially saturated gas contains quantity of water vapor which is less than that present under saturated conditions, but more than dry gas Spectator water: is the water carried by the gas or air that feeds the combustion reaction. Spectator water does not contribute to the gross calorific value. FLOW EQUIPMENT LEADERSHIP

Hydraulic Systems Manufacturer

Wickwar • Aberdeen • Great Yarmouth • Dubai • Dammam • Moscow • Singapore

74 | Automation INSIGHT! | decEMBER 2013

www.alderley.com

Customer Service

Calorific Value Calculation:

The calculation method and physical properties of gas components used in calculation may be on the basis of relevant ISO/ GPA standard or as agreed in the sales gas agreement. Generally chromatograph analysis of natural gas provide light hydrocarbon component details up to C6+ / C9+ and non-hydrocarbon components like CO2 and N2. Natural gas is analyzed using separate analyzers

Delivering new measures of success Upstream to downstream, onshore to offshore, count on Cameron for complete valve and measurement expertise. We offer the broadest range of quality solutions in the industry. Life cycle management programs. And the unmatched experience that comes with solving problems for our customers around the globe. www.c-a-m.com/vm

BROADEST PORTFOLIO OF VALVES PREMIUM BRANDS VALVE AUTOMATION MEASUREMENT SYSTEMS CAMSERV™ SERVICES

december 2013 | Automation INSIGHT! | 75

RAISING PERFORMANCE. TOGETHER™

Custody Measurement Calculation approach:

Calculation approaches, as described below, may be used when basis of calorific value to be reported and actual water contents are different. The methods illustrated are not exclusive or exhaustive in nature. Each company should develop its own approach consistent with the gas sales agreement. Base temperature for the illustration purpose considered to be 60o F in this paper.

(A) Gas is dry:

For the practical purpose, when the gas has moisture content less than 7 lbs/MMscf of gas, it may be considered as dry and actual moisture content may be ignored. However, if sales gas agreement requires actual water content to be considered, follow the calculation method as provided in other section of this document. Before using gas composition in the energy value calculation, normalize the gas composition from GC (hydrocarbon components up to C6+ /

76 | Automation INSIGHT! | decEMBER 2013

Custody Measurement Calorific Value per unit volume of dry gas

C9+ and inert gases like CO2 and N2) and other contaminants like H2S. Calorific value of dry gas is than calculated as per relevant ISO/ GPA standard or agreed method. The calculation would provide calorific value of dry natural gas per unit volume.

Decreased calorific Value per unit volume water saturated gas Unit volume of dry gas

Total energy value on dry basis: Total energy can be obtained by multiplying volume of dry gas by the calorific value per unit volume of dry gas, both being at base condition of temperature and pressure Total energy value on saturated basis: As the dry gas is assumed to contain moisture content until its saturation, it is necessary to adjust calorific value of dry gas to account for the fact that water would have displaced some gas, thus lowering the calorific value per unit volume of gas. Unit volume of dry gas shall be increased to accommodate the moisture till gas is saturated with water.

Increased volume of dry gas after saturated with water vapor Fig. 1 Fig. 1 provides graphical representation of the change in calorific value and volume of the unit quantity of gas when water saturated.

Change in Calorific Value:

To convert calorific value of gas from dry basis to water saturated basis at base condition, use equation (Eq. 1).

Table 1 Base pressure in Psia

14.696

14.73

Conversion factor

0.9826

Water Saturated calorific value = Dry calorific value * Conversion Factor -------- Eq (1) Where, conversion factors for various base pressures are provided in Table 1.

Table 2 Base Temp in °C

Conversion factor

0.9940

0.9832 0.9769

25 0.9687

If the base temperature is different than 60 °F, use conversion factor as per Table 2 for base pressure of 14.696 Psia

december 2013 | Automation INSIGHT! | 77

Custody Measurement

Change in Gas Volume:

When gas is saturated with water, volume of dry gas shall be increased until moisture vapor saturation point To convert gas volume from dry basis to water saturated basis at base condition, use equation (Eq. 2). Water Saturated volume of gas = Dry gas volume * Conversion Factor -------- Eq (2) Where, conversion factors for various base pressures are as per Table 3 Table 3 Base pressure in Psia

14.696

14.73

Conversion factor

1.0178

Total energy of assumed water saturated condition can be obtained by multiplying volume of saturated gas by the calorific value per unit volume of saturated gas, both being at base condition of temperature and pressure.

(B) Gas is partially saturated with moisture: For the practical purpose, when the gas has moisture content more than 7 lbs/MMscf of gas, but less than saturation point, gas is considered partially saturated. As the water vapor has displaced the gas component, gas energy content would be lower. One of the common methods of calculating actual calorific value of partially saturated gas is normalizing gas components including water content but not using water calorific value while calculating total calorific value per unit volume of gas.

Where, Water vapor volume per unit mass of water can be obtained from table 4. Table 4 Pressure (Psia) Volume of water in ft3 per lbs of water at 60 oF (Water Vapor Volume=Vwv)

14.65

14.696

14.73

15.025

21.13065 21.06454 21.01591 20.60327

Other consistent method of calculating actual calorific value of gas is normalizing gas components excluding water content and derives calorific value of assumed dry gas. Actual calorific value can be derived from the dry gas calorific value by (Eq. 5) Actual calorific value = Dry calorific value / Conversion Factor -------- Eq (5) Where, Conversion Factor = 1+ (Vwv /1,000,000)*Water Content in lbs/ MMscf -------- Eq (6)

• Natural gas is considered dry when it contain moisture less than 7 lbs per MMscf of dry natural gas • Gas saturated at flowing condition does not contain as much water as gas saturated at standard condition

Conclusion This article provide general guidelines on energy value calculation of natural gas when it consists of water vapor at the level which is different than as required for reporting defined in the gas sales agreement. Total energy value of natural gas can be obtained by multiplying volume of gas by the calorific value per unit volume, both being at the same conditions of pressure, temperature and water content. To calculate total calorific value of gas, a gas volume containing water vapor (wet volume) must be multiplied by a wet calorific value. If the gas volume is compensated by mathematically removing the water vapor, then the dry calorific value must be used to calculate total energy delivered. It is technically consistent to apply one or the other.

Bibliography:

1. IS0 6976:1995: Natural gas - Calculation of calorific values, density, relative density and Wobbe index from composition 2. GPA 2172–09: Calculation of Gross Heating Value, Relative Density, Compressibility and Theoretical Hydrocarbon Liquid Content for Natural Gas Mixtures for Custody Transfer 3. AGA Gas Measurement Manual – Part XI, Measurement of Gas Properties

Author: Chandu Bhatasana,

has 20+ years of experience in Metering & Instrumentation. He has been working with Saudi Aramco as Metering Engineer. He can be reached at e-mail : Chandulal.Bhatasana@Aramco.com

Where, Water Vapor Volume per unit mass of water can be obtained from table 4. Calorific value of water saturated gas from dry gas calorific value may be derived using Eq (1)

Important figures and facts:

• One pound of water vapor at 14.73 psia and 60 oF occupies about 21.01591 cubic feet of volume. • Natural gas that is saturated with moisture at 14.73 psia and 60 oF contains about 828 lbs of water per MMscf

Saturated calorific value from actual calorific value may be derived using Eq (3) Water Saturated calorific value = Actual calorific value / Conversion Factor ------ Eq (3) Where, Conversion Factor = (1- {Vwv /1,000,000}*Water Content lbs/MMscf)/0.9826 -------Eq (4)

78 | Automation INSIGHT! | decEMBER 2013

december 2013 | Automation INSIGHT! | 79

Invensys Triconex: 30 Years in Revolutionizing Safety Industry-leading solutions provide 600 million hours of safe, available and secure manufacturing operations -Industrial organizations today are consistently taking steps to prevent the risk of danger, injury, or damage in the plant environment. In so doing, these organizations rely on trusted experts to provide a sophisticated, robust defense against potential hazards. Renowned for setting the bar high in safety and critical control, Triconex develops safety systems that establish reliability and availability standards, earning Invensys the hard-won reputation for unparalleled dependability in critical applications that safely shut down burners, turbines or other equipment in the face of emergencies. Invensys leads the market when it comes to overall safety instrumented systems. As one of the world’s most rigorously evaluated safety systems, more than 13,000 Triconex controllers are in use today in safety and critical control applications worldwide, and they have collectively amassed more than 600 million hours of safe operation. Through its Triconex solutions, Invensys helps clients achieve continuously safe, available and secure production, while increasing asset uptime, improving production output and maximizing return on assets. “Triconex has always been identified as a premier system for industrial safety and critical control,” said Harry Forbes, senior analyst, ARC Advisory Group. “The merits of various system architectures are always debated, but Triconex safety systems have always provided high levels of safety, availability and reliability. ARC believes these are the reasons Triconex safety and critical control systems, solutions and turbomachinery applications are globally respected and recognized by end users in a wide range of industries and applications.” The Triconex brand was born in 1983 when Jon Wimer gathered a team of talented engineers, developers and professionals to build the world’s premier industrial safety system. In 1994 Triconex was acquired by Siebe plc of the United Kingdom. In 1999 Siebe and British Tire and Rubber, another British engineering firm, merged to form Invensys plc. Together with the other Invensys brands, including the company’s Foxboro, SimSci, Wonderware and Avantis offerings, Triconex systems enable Invensys clients to integrate their control, automation and business management technologies so they can improve the safety, efficiency and profitability of their operations in real time. “For 30 years, Triconex solutions have been helping manufacturing and process facilities manage the risks and hazards associated with automating, controlling and improving their operations,” said Gary Freburger, president of Invensys’ systems business. “We are proud that our solutions have helped thousands of customers avoid unscheduled downtime, maximize asset performance and improve process efficiency while protecting the safety of their people, their communities and the environment.” Other groundbreaking Triconex solutions include the Tricon controller, a state-of-the-art fault-tolerant controller based on triple modular redundancy architecture. It is the first completely triple redundant, industrially ruggedized and cost-effective system in the

advanced applications

The Future of Automation is Now!

To understand the current state of process automation we start by examining the history of automation technology in the context of the business drivers over the past half century that are responsible for the evolution—and, in some cases, revolution—of this technology. We then look at advances in measurement systems and the new classes of variables, e.g., indicators of financial performance, that are being brought into the process automation systems to address the current business drivers and competitive pressures affecting process plants. These advances—coupled with the effect of changes in the speed of information access and sharing—demand that a new perspective on operations be adopted. This, in turn, is driving further evolution of automation system capabilities and an increasing reliance on

value-add applications to both improve and provide real time feedback about the economic performance of process plants. Taken together, this nexus of business drivers and technological advancements has resulted in a new class of automation technology, i.e., an Enterprise Control System, which provides the foundation for Production Operations Management whose purpose is to effectively close the “business control loop.” This will greatly facilitate collaboration for improved decision making and enable companies to manage their processes as a business, just as they manage their business as a process.

Brief History of Automation Technology Over the course of the last 60+ years the primary focus of companies in the hydrocarbon processing industry has changed in response to competitive pressures. In the middle of the last century these companies made significant investments in product chemistry and R&D activities to create molecules with commercial appeal. The industry was focused on “what to make.” In the latter decades the emphasis shifted to one of “how to make it.” Process efficiency and cost management became strategic initiatives. Today, global competition and economic uncertainty have made it an imperative for companies in the HPI to devote their energies to maximizing profits by optimizing their operations. This shifting focus is illustrated in Figure 1 below.

Authors:

Donald C. Clark, Invensys Operations Management Dr. Martin A. Turk, Invensys Operations Management

Don has over 38 years of user experience on the IT side of process operations with various companies from both the end-user and vendor communities. Don obtained his BS degree in Chemistry at California State University, Fullerton in 1973, and his MS in Chemical Engineering from the University of Houston, Texas, in 1975. Martin A. Turk, Ph.D. Director, Global Industry Consulting, HPI Invensys Operations Management, Houston, TX For most of his 40+ years of experience, Dr. Turk has been involved in engineering, consulting, sales and marketing activities related to process automation. These activities include process simulation, advanced control and information/ automation system strategic planning. He is currently the Director, Global Industry Consulting, HPI, for Invensys. 82 | Automation INSIGHT! | decEMBER 2013

Introduction Regulatory control systems—from pneumatic single loop controllers to modern distributed control systems—have proven to be very successful in managing the basics of plant operations, regardless of the nature of the processes involved. Over time, technological advancements have enabled dramatic improvements to be made in the functionality that process automation systems provide, enabling them to performing increasingly complex tasks. However, until recently, the primary purpose of these systems has been to control process variables, such as temperatures, pressures, levels and flows, with the goal of achieving stable and safe plant operations. In response to the myriad of internal and external pressures that today affect the performance and competitiveness of process plants, automation systems are undergoing significant enhancements and expansions of their functionality. The emphasis in the past was on improving process efficiency while in the future it will focus on improving business performance. And, you have to have the former before you can hope to get the latter.

Driver in the Process Industry

Donald C. Clark, Invensys Operations Management

What to Make

How to Make it

1950

1975

Key Considerations

• Product Chemistry • R&D excellence

• Process Equipment • Cost Management

at their target values—in the face of measured and unmeasured disturbances—using straightforward single loop, feedback PID control strategies. This approach produced satisfactory results as long as concerted efforts were made to keep the control loops correctly tuned. Such regulatory control systems remain a key component of all process automation architectures.

As process technologies became more complex in response to competitive pressures to improve product quality and yields while reducing operating costs, greater demands were placed on process control How to Make it Profitably systems to be able to manage these processes at the higher levels of performance required to meet their operating objectives. As a result, significant advancements were made in the mathematics of process control (e.g., Decoupling Control, Relative 2010 Gain Array and Dynamic Matrix Key Considerations Control) and in the systems used • Optimized Operations to execute these “advanced” control Control strategies. • Profit/Margin Management

Figure 1: Evolution of Process Industries Drivers

Simply put, this evolution of business drivers has shifted company strategies from those focused on improving process efficiency to those focused on improving business performance. These evolving strategies have had profound effects on organizations and the technologies they need to achieve and maintain competitiveness. Let’s take a brief look at the resulting changes in automation technology. In the 1950s, prior to the advent of the “digital age” in process automation, control systems were designed to hold process conditions

It was in the 1960s that the first digital computers were used for implementing advanced regulatory and supervisory process control strategies. Within a couple of decades, as the power of process control computers increased and the first distributed control systems were introduced, control theory had produced a working version of dynamic matrix control to better handle the interactions of multiple manipulated and controlled variables in complex processes, particularly those used in petroleum refining. This technology remains the preferred december 2013 | Automation INSIGHT! | 83

Advanced Applications

mathematical construct for implementing multivariable predictive control in refineries and petrochemical plants.

Today’s world-class plants are very large in size to capitalize on economies of scale and reduce unit costs. These plants now have the ability to measure and report in near realtime on the economic performance of the facility. This has transformed automation systems into ones that close the business control loop. A graphical depiction of the business control loop is given in Figure 2. As a result, there is more emphasis on availability and reliability of the plant, and the entirety of the “IT platforms” to maximize utilization. Plants are being operated with longer run times between shutdown, faster changeovers, accelerated startups and smaller operating crews. All of these factors have increased dependence on advanced control, optimization and dynamic simulation. Properly managed, such plants are great sources of value. However, there is also the potential for large negative financial impact when failures occur.

These advancements in automation technology have produced significant improvements in the control of complex processes. However, the use of this technology has been to improve process efficiency, primarily aimed at reducing operating costs. While the number of process measurements accessed by the control systems has increased over the years, by and large, the types of measurements have not changed much. Key measurements that have been absent from the operators purview are those that indicate the economic impact of each of their actions (e.g., changing controller setpoints or making manual adjustments to manipulated variables). They have not been provided with cost and/or profit control loops that are not only connected to state variable measurements, but also to stream property measurements. However, this situation is changing. Enterprise/ Supply Chain Optimization

Automation of the business control loop enables both plant-level and corporate-level personnel to manage the “process as a business” by providing them with a view of the process in the context of business variables, assuming such measurements are available. Figure 2: The Business Control Loop

EPS Calculator

Forecast

Actual

Earnings per Share

Executive Level

∆ = Actual - Forecast = Variance

Actual

Forecast

Business Management Level

∆ = Actual - Forecast = Variance

Process Optimization

Energy Cost Contribution to Mfg. Cost

Raw Mat’l Cost Contribution to Mfg. Cost PV

PV SP ∆ = PV - SP = Deviation

Regulatory & Advanced Process Control

∆ = PV - SP = Deviation

Column 301-D Reboiler Outlet Temp. PV

KPIs

Throughput (Fixed Cost Contribution to Mfg. Cost)

Plant Management Level

Process Management Level

∆ = PV - SP = Deviation

It has been shown in actual practice that giving trained and empowered plant operators realtime information about the economic impact of their decisions (i.e., Dynamic Performance Measures) allows them to improve process profitability without any changes to their process control 84 | Automation INSIGHT! | decEMBER 2013

Effective execution of the business control loop increases reliance technology is advancing at a rapid pace such on a rich set of applications that are designed to streamline and that robust, relatively inexpensive stream automate the “business of the business” (refer to Figure 3). With time, property measurement sensors will soon become the content of the information in these applications also increases. commonplace in petroleum refineries and With this increase in the richness and capability of the needed petrochemical plants. These measurements applications, there has been a proportional increase in both total I/O will facilitate the ability of operations personnel count in a plant, and in the I/O ratio. In the early days, typical I/O to make decisions based on profitability, not ratios were about 1-2:1, with I/O counts on the order of 4,000. Today, expediency. the ratios are 7-9:1, and the counts often exceeding 75,000. Why? Plant Driven by Process Variables Plant Driven by Business Variables Because the applications demand Increasing Information Content an ever increasing amount of input information to deliver the functionality demanded of them. Early Control Central Computing DCS Desktop Internet Furthermore, to improve visibility into the business performance of the plant, it is necessary to have better measurements of the properties of the process streams that provide the value uplift for which the plant was designed. Online process measurement

Utilization of Solution

APPLICATIONS

Data Load = I/O count, I/O ratio, History, Visualization, Property: State Ratio, etc. Levels of Integration

Figure 3: Growing Reliance on Applications Drives Increasing Data Load

A New Perspective on Operations

Gross Profit

Performance Measures

Asset Optimization

Gross Profit Calculator

The Changing Nature of Process Measurements

systems. Sasol Infrachem implemented a relatively inexpensive DPM system in several of its steam plants and realized a benefit of millions of dollars per year which paid for the project in a couple of weeks! As a result of this outstanding success the company has continued to invest in DPM systems in other process facilities with equally compelling benefits.

One of the key driving forces responsible for the changing nature of automation systems—going beyond control of processes to control of business performance—is the dramatic reduction in the time constant of information flow across the globe. It wasn’t too many years ago that it took days for information to travel from one part of the world to the other. This relatively long time constant of information flow (τIF) enabled petroleum refiners and petrochemical producers sufficient time to respond to events that affected them since the time constant of the refinery’s or petrochemical plant’s decision making process (τDP) was shorter than τIF. Telex and facsimile transmission reduced the τIF somewhat, but plants were still able to respond in a timely manner. As little as 20 years ago no one in the HPI spoke about the need

for agility to achieve and sustain competitiveness. But, as the saying goes, “times have changed.” Today, information flow across the globe is, for all intents and purposes, instantaneous, such that τIF is approaching zero. The same cannot be said for τDP. While automation technology has enabled τDP to shrink, it is still large compared to τIF. It is not surprising that many HPI facilities have either changed hands or shuttered due to their lack of competitiveness and profitability. The challenge remains to continue to cost-effectively apply automation technology, information management tools and modern decision making paradigms in ways that further reduce the value of τDP.

Your Choice…a Patchwork of Applications or an Enterprise Control System One of the primary causes of a high τDP is the fact that many of today’s HPI facilities and businesses are managed using a patchwork of loosely coupled applications. While these myriad of applications— some of which are “mission critical”—may be connected to plant information and/or corporate business networks, Microsoft Excel® remains the preferred mechanism for sharing information among these applications. This is not only time consuming and manpower

intensive, but lacks the robustness and cost effectiveness demanded of high-performance companies. The good news is that the industry is at the nexus of a technology revolution that has finally enabled realization of the vision of an integrated december 2013 | Automation INSIGHT! | 85

Advanced Applications

Due to these technologies it is now possible to tightly couple business performance/strategy with process efficiency/execution via a Production Operations Management—Enterprise Control— System (Figure 4). This “system of systems” is based on the modular integration of applications that are custom-tailored to industry needs. Empowered individuals at all levels of the organization now have the capability at their fingertips to measure business performance in near realtime and then

Business Performance

STRATEGY

Handled by ERP Systems (1990’s)

Years/ Months

Production Operations Management aka “The Future”

Time

Service Oriented Architectures; Cloud computing; Solid-state high speed memory devices; Parallel computing; Virtualization; A wealth of off-the-shelf hardware platforms and software applications; Definition and wide-spread acceptance of industry standards (e.g., S95) that allow for greater interoperability and lower costs; Wireless communications; Cyber security.

Customers

• • • • • • • • •

use this information to make decisions and take actions quickly and correctly in order to correct for deviations from plan or reinforce positive behavior. The net result is a significant decrease in τDP which makes an organization more responsive to market forces and, therefore, better able to compete in the global HPI.

Suppliers

enterprise control system…what we referred to several decades ago as CIM, Computer Integrated Manufacturing. This revolution includes:

Measure... Empower... Improve Handled by DCS/PLC Systems (1980’s)

Seconds Process Efficiency

EXECUTION

Figure 4: Production Operations Management System

Other benefits of an enterprise control system are crossdisciplinary collaboration enabled by new visualization techniques and new tools to convert vast amounts of data into information. Agility is enhanced by being able to make use of remote expertise (i.e., bringing the problem to the expert) and decentralized, but coordinated plant operations.

The Future is Now! Realtime is the new frontier of sustainable value creation. An enterprise control system extends the control loop concept into the business of operations. It enables understanding of… • The What – business variances right now, i.e., the right information, to the right people, at the right time, in the right context; • The Why – root cause connections to variances. And it provides the ability to… • Control/automate the routine; • Look forward/set most profitable pathway. This new way of doing business allows companies in the HPI to identify future profitability opportunities and have a small enough τDP to take advantage of them. The result is faster “time to profits.”

86 | Automation INSIGHT! | decEMBER 2013

Benefit sources include: • Cross-platform integration; • Real-time schedule feed forward from operations, not just to operations ; • “Built-in” robustness and fault tolerance; • Smarter asset management maintenance strategies – device level and up; • Dynamic simulation, on-line optimization for process and business – to run on-line “What if ” scenarios; • Inventory reductions; • Ability to quickly and correctly identify the “point-of-no return” on operating costs; • Running a virtual “single plant” across many actual sites/ locations; • Quality improvement (waste â, yield á); • Enhanced cyber-security; • Agile realtime business finance visibility of asset utilization. In summary, automation moves into asset optimization; it spans all elements of operations; it becomes the vehicle to run your process as a business. The future of automation is now and it is indeed bright!

technology and Technologyimplementation and Implementation

Integrated Electrical and Automation Systems Authors:

Tom F. Nestli, ABB AS Process Automation Division Peter Tubaas, ABB Corporate Communications

MS Nordlys, one of the ships of Hurtigruten - The Norwegian coastal ship operator entering the port of Hammerfest.

As process plants get larger and more complex, automation systems must handle an ever-increasing number of signals. At the same time, the number of electrical consumers increases, making an electrical control system essential. The electrical control system is an automation system in itself providing an interface between the process control and the electrical consumers and actuators. ABB takes responsibility for all these systems and their integration. By letting ABB handle the integration and all the interfaces, customers benefit from faster project execution, reduced re-engineering, higher quality, and higher operational efficiency. Electrical systems are clearly a core part of any process plant, providing electrical energy to drive motors, energize heaters, power lighting and auxiliary equipment. The electrical system is invariably complex, relying on thousands of components and kilometers of cabling. The complexity of the system increases with the size of the process plant. Such large process plants are reliant on automation systems to operate efficiently and safely. These automation systems will typically respond to tens of thousands of signals in a quick, predictable and reliable manner. The seamless integration of the electrical and automation systems are highly desirable in a process plant, a benefit recognized by ABB at the Statoil Snøhvit – or Snow White – liquefied natural gas (LNG) 88 | Automation INSIGHT! | decEMBER 2013

plant. Here, the Electrical Control and Supervision System (ECSS) communicates with a wide range of equipment and ensures a stable power supply to the LNG facility.

Snøhvit The Snøhvit field – named after the fairytale character Snow White – was discovered more than 20 years ago. The road to develop this gas field has been long and winding, but the procet is finally close to production start. It is planned to go on-line during the summer of 2007. The past few years have turned the uninhabited island of Melkøya(1), not far from the town of Hammerfest, into the largest building site in Northern Europe, and the largest construction

(1) Map of Northern Norway

project that Norway has ever seen.

of security and minimal downtime.

Soon, gas from the Snøhvit field, approximately 140 kilometers offshore in the Barents Sea, will be flowing into the gas processing plant for treatment and shipping to the global LNG market. The core products of the plant will be liquefied natural gas (LNG, 5.67 billion m3/year), liquefied petroleum gas (LPG, up to 250,000 tonnes/year) and condensate (up to 900,000 m3/year). All products will be exported by ship.

The philosophy of process plant owners in general, and Statoil in particular, is to provide its operators with a “single window” into the plant. ABB’s 800xA Extended Automation system provides this facility and was, therefore, chosen for the Snøhvit project.

Snøhvit is the first development in the Barents Sea. The oil and gas fields were discovered in the early 1980ies. Combined with the adjacent Albatross and Askeladd fields, Snøhvit contains more than 300 billion m3 of natural gas. Gas will be extracted from the seabed using subsea equipment, which are operated remotely from Melkøya. The subsea subsea control system was delivered by ABB in the UK (now Vetco Aibel). The topside of the subsea control system, which is an integrated part of the overall Safety and Automation System (SAS), was delivered by ABB in Norway.

Complete control of the plant Snøhvit is an extremely complex installation. The process is extensive, encompassing subsea control processing, complex LNG processes, and storage and loading of the final products. No system is more critical to the processing plant than the combined safety and automation system. The number of signals running through the Snøhvit process is enormous; the Process Control and Data Acquisition (PCDA) system has to handle more than 30,000 signals simultaneously. An unscheduled halt in production is extremely expensive. Therefore, ABB’s control systems are constructed and tested to provide the highest level december 2013 | Automation INSIGHT! | 89

Technology and Implementation

Plant power demand Complexes for liquefied natural gas require a reliable and stable energy supply. Most LNG plants are, however, situated in areas in which the power supply is either unreliable or non-existent. The Snøhvit plant is no exception and must, therefore, rely on its own power supply. To meet the power demand, the Snøhvit plant contains a 1.65 TWh power plant with five gas turbine-driven generators of about 50 MW each. These power the large refrigeration compressors of up to 65 MW, driven by variablespeed electrical motor, that are required to liquefy gases. The hot exhaust gases from the gas turbines are used to provide to heat for other parts of the process. This set-up saves energy and provides about ten additional up-time days per year due to the much higher availability of electrical drivers (as compared to gas turbine drivers). The Snøhvit plant not only includes its own power station and large compressor drivers, but also a large distribution network with several thousand relatively small electrical consumers. A large variety of ABB electrical components are included in ABB’s deliveries to the plant. These include high voltage switchgear of the EXK-0 type, rated for 145kV, and medium voltage switchgear of the UniGear ZSI type, rated for 6.6kV and 11kV. Also included are optic arc detection systems to provide early detection and quick protective action of switchgear to extinguish arcs. Further, MNS type switchgear is used at low voltage levels of 400 V and 690 V. Some 500 cubicles supplying power to about 2,500 consumers are included at these voltage levels; of which some 600 consumers An ABB engineer taking an overview of the plant at Melkøya.

Technology and Implementation

are Insum starters (intelligent motor starters) and 75 consumers are variable speed drivers of ACS 800 type. ABB’s protection and control unit (REF542) is used throughout the plant to provide the highest level of security and selective protection actions in the event of a fault in the power system.

Electrical control and supervision system The complex nature of the electrical system requires an automated ECSS. This system is required to unite the thousands of motors, switches, contactors and circuit breakers, and to minimize the effects should a fault develop. A single unscheduled shutdown for the entire plant is extremely expensive. The ECSS is at the heart of the electrical system and communicates with the vast range of ABB products using serial links and Ethernet. It is also linked with the automation system and other third-party deliveries. The system consists of 48 AC800M controllers. The ECSS processes some 44,000 signals at any onetime – more than the plant’s automation system. The ECSS provides a wide range of functions, enabling a stable power supply to the plant, lowering operation costs and reducing emissions, while at the same time increasing safety. An important part of the ECSS is the Power Management System (PMS). Since a relatively small fault may lead to a cascade of equipment shutdowns that could affect a large part or the entire plant, faults must be handled quickly and appropriately to avoid a domino effect. ABB’s PMS is also based on the 800xA Extended Automation system and is designed to monitor, control and protect all sections of a process plant. It includes functions such as: • Supervisory control and data acquisition (SCADA) including generator, circuit breaker, mode and motor control • Power control, including tie line control, peak shaving and load sharing • Load shedding, including fast, slow and frequency based load shedding, as well as manual load shedding Two ABB engineers discussing the plans for the day at the LNG plant in Melkøya.

Probably one of the most important and most frequently relied upon parts of the PMS is the load shedding function, which helps ensure that the consequences of any one fault in the electrical system has the smallest possible impact on the functioning of the plant. ABB has delivered and commissioned more than 30 PMSs worldwide, demonstrating that the PMS substantially improves plant uptime, efficiency and reliability. The ECSS not only provides an interface between the process plant’s automation and electrical systems; it also provides indispensable functionality and reliability in a plant where a system shutdown could cost millions of dollars. Although full communication and data exchange with the process plant’s automation system is provided, the ECSS is not depending on it to operate. On the contrary, the ECSS can operate in isolation to ensure safe and reliable operation of the electrical system.

ABB at the cutting edge ABB can draw on more than 50 years of experience with automation and electrical systems to optimize their integration. Uniting the electrical and automation systems is becoming a necessary feature of large process plants. Operating such plants without an automated system is almost unthinkable, not only for safety reasons, but also for reasons of cost savings and increased efficiency. Customers like Statoil rely on experienced companies like ABB to ensure safe and reliable plant operations.

Main electrical vendor approach In the past, oil companies and engineering, procurement and construction (EPC) contractors have very often purchased different types of equipment (e.g. transformers, high voltage switchgear, medium voltage switchgear and low voltage switchgear) under separate contracts. Project risks can be reduced, however, by including most of the electrical equipment and systems – as well as engineering – under one large contract. The result is lower costs and faster project execution with safer systems that are fully integrated and interoperable. Safety is improved during installation and commissioning since project co-ordination is more easily achieved with only one contractor. Statoil recognized the merit of such an approach and merged all purchases of high voltage, medium voltage and low voltage switchgear, as well as the ECSS, for the Snøhvit project into a single contract. In addition to equipment delivery, ABB has provided a wide range of engineering services including a long list of electric network studies. These are required to ensure safe operation and maximum efficiency of the plant. Since the Snøhvit plant is physically connected to the northern Norwegian power grid, it soon became of interest to study the dynamic behavior of the entire plant – including the gas turbine generator sets – and its connection to the grid. ABB has performed a dynamic stability study that was used to set and adjust the parameters of the power management system, as well as the dedicated generator control algorithms. This ensures not only stable operation of the process plant, but also ensures that the process plant contributors to the sustainability of the northern Norwegian power grid – as required by the grid operator.

90 | Automation INSIGHT! | decEMBER 2013

december 2013 | Automation INSIGHT! | 91

Installation, Operation and Maintenance Issues

Figure 1. AUMA Actuators installation Oil & Gas Industry

Electric Actuators in Asset Management Systems Today, data collection and safeguarding is like child’s play. Drawing correct conclusions is more difficult though. The case must be solved by both the secret services and the operators of process plants. In this article however, we do not want to deal with the problems of secret services but present the actions taken by AUMA as electric actuator manufacturer to make sure that the devices supply the plant operator and the service staff with useful information on device status. Electric actuators are used for valve automation in a multitude of process applications ( Figure1). They are composed of a gearbox with flange mounted electric motor and integral control, which contains the switchgear for motor control and the communication interface to the DCS. Interfaces for all conventional process automation fieldbus system are available, like Foundation Fieldbus. However, traditional parallel control is still used. Electric actuators are always equipped with a hand wheel and on activation mechanism to allow for modification of the valve position in the event of power failure The integral controls either control the actuator via the binary operation commands OPEN - STOP- CLOSE, or a valve position to 92 | Automation INSIGHT! | decEMBER 2013

be approached is defined by the DCS using a set point. The controls perform actuator positioning. Upon reaching a valve end position, the actuator is switched off automati¬cally, either via position feedback signal or when reaching a pre-set torque limit. Modern actuator controls ore equipped with micro controllers. Since their introduction about 20 years ago, the functionality of actuators has been extended tremendously. Already in the december 2013 | Automation INSIGHT! | 93

installation, operation and maintenance issues

Installation, Operation and Maintenance Issues

1990s, the basic facility of preventive maintenance by logging and assessing operating data of field devices was identified. Due to the development of Fieldbus systems, the technical prerequisites were created to transmit a larger number of status data from the field device to the DCS than via parallel communication. This created the basis for asset management using the existing & same cable infrastructure to the field devices.

• Failure: Due lo functionality failures within the device or the peripherals, the device cannot be controlled from the control room. This is a well-known fault signal.

ONLINE PLANT ASSET MANAGEMENT This topic is keeping a lot of people very busy with the development of guidelines for implementing asset management systems. The basics are always the same. Seen from the perspective of the field device manufacturer, the online plant asset management, also called plant asset management, is of particular relevance.

Intelligent Electric Actuators Figure 2: The new Generation .2 actuators support asset management

Within this context, assets ore considered as plant components relevant to on industrial process such as apparatus, vessels, machines, piping and process control technology instruments and equipment. The objective of online plant asset management is to pre· serve or enhance the value of a plant by undertaking maintenance measures. As a general rule, online plant asset management uses at least ports of the infrastructure facilities for process control, however with separate management. Whereas process-relevant data is processed in process control to ensure coordinated performance, on asset management system provides above all online information for the technical assessment of plant components. This is in the authority of plant engineering, whereas process control lies within the responsibility of the plant operator.

Up to now, technical plant engineering performed regular maintenance tasks and reacted once a failure occurred by removing the cause of failure. Important and costly plant downtimes can be the consequence. As a matter of fact, an asset management system has two tasks: To signal conditions causing a failure so that measures these situations, and on con be taken to prevent the other hand to supply complex information on the maintenance requirement of a device to eliminate the static maintenance intervals. 94 | Automation INSIGHT! | decEMBER 2013

Modern electric actuators (Figure 2) are field devices with internal status monitoring, e. g. they monitor independently that specified operation conditions are met. This includes the respect of pre-defined operation times or the recording of the number of starts. These variables are easy to record with the available microcontroller technology. Monitoring other variables require additional hardware within the actuator. Apart from the existing torque monitoring, sensors for and continuous recording of temperatures and vibration sensor are available. Consequently, all conditions are fulfilled to supervise all variables which could cause failures. Device status assessment requires exact knowledge of the service history.

The device manufacturer must classify the status signals of his/her devices using these categories. For example, if an actuator senses an ambient temperature out of device specification, the plant operator will, receive the respective symbol with the device identification. He will inform the plant engineering accordingly and they have to investigate the origin. A similar procedure will occur if the torque is out¬side the tolerance band width around a reference characteristic. Monitoring actuator specific service condition and limit as well as the indication of events according to NE 107 categories are implemented. The additional maintenance information supports the technical engineering in scheduling maintenance measures by indicating the wear of the equipment.

Unambiguous Communication

Figure 3: The new generation of actuators uses the NAMUR 107 reporting system

Figure 4: Symbols in compliance with NE 107 status signal classification (Left to right); out-of spec, maintenance required, function check, failure.

Exceeding predefined limits are spontaneous events. These events must appear on the plant operator dis¬play to allow for immediate introduction of corrective actions. Considering that a plant consists of a multitude of components made by different manufacturers, it becomes obvious that device feedback must comply with defined schemes. The objective is that the plant operator can take appropriate actions to eliminate the problem. One approach is to classify status signals into four categories, in compliance with NAMUR recommendation NE 1 07: • Out of specification: Deviations from the permissible application conditions determined by the device itself through self-monitoring. The device can still be controlled from the control room. • Maintenance required: The device can still be controlled from the control room. The device must be inspected by a device specialist to avoid any unscheduled failure. • Function check: Due to ongoing work on the device, it cannot be controlled from the control room at that very moment. december 2013 | Automation INSIGHT! | 95

We create

ex standards

the solution

the leadership of convenor Dr. Ulrich Johannsmeyer in Northbrook. Here, the standard requirements already existing in the individual standards were collated. With regard to the terms and definitions, these were adapted according to the IEV dictionary to achieve clarity. A listing of permissible electrochemical systems was prepared. The next objective of the AHG 37 is to provide unified requirements for the corresponding chapter of the IEC 60079-7: ›Increased safety‹. This standard was chosen as it is to be published next of all the main standards.

AHG 38: Luminaires

Ex-News

Information about explosion protection Author: Thorsten Arnhold (Editorial Board)

IEC TC 31 Equipment for explosive atmospheres TC 31 met in April 2012 in Northbrook (USA) and in October 2012 in Oslo (Norway). As part of this event, the following working groups (WG) held meetings:

WG 32 Creepage and clearance distances:

After having prepared and discussed a first internal working document in the working group, TC 31 now assigned the task to prepare an informal document for distribution to the national committees, which was issued in January 2013. Further editing will take place during the coming spring meeting in Windsor (UK).

Ad Hoc Working Group (AHG) 33: Safety Devices Related to Explosion Risk:

The management of the AHG was newly appointed in Oslo: the new rapporteur (designation for the chairman of an AHG) is now Otto Walch from Germany. Based on the European Standards EN 50495 and EN 13463-6, a new working paper is now to be prepared which is to be presented at the autumn meeting of IEC TC 31 in New Delhi (India).

AHG 34: Very low ambient temperatures

After the AHG had published a Draft Technical

98 | Automation INSIGHT! | decEMBER 2013

Specification in the spring of 2012 under the title: ›Equipment intended for use in explosive atmospheres in climatic regions of the world with a low value of ambient temperatures below – 20 degrees Celsius‹, a decision was taken at the meeting of the TC 31 in Oslo, to establish a new WG 39 with the title: ›Adverse service conditions‹ under the convenor Dr. A. Zalogin (Russia), which has set its constituting meeting for March 2013 in London. The WG has been assigned a very challenging task as the scope was extended considerably: ›To investigate the issues associated with the influence of environmental factors in adverse service conditions related to equipment, installation and maintenance in the IEC 60079 series and ISO/IEC 80079 series‹. So, we are not only talking about the range of extremely low temperatures, but also about numerous other environmental influences, such as wind load, humidity, vibration etc. If the document to be prepared is to offer a valuable contribution with added practical benefits, then it will have to differ considerably from the present document. This contains mainly functional requirements on 58 (!) pages which are based on Russian Ghost Standards and include major overlap with the series IEC 68 (Environmental testing standards). A ›Call for experts‹ has been published.

AHG 37: Electrochemical cells and batteries in equipment for explosive atmospheres

The first meeting of the AHG 37 took place in April 2012 under

According to a resolution by TC 31, the AHG will be incorporated in the WG 40 with the following scope: ›To review and develop requirements for luminaires for explosive atmospheres‹. The ›Call for experts‹ was made in November 2012. G. Schwarz from Germany will be the convenor of the WG.

AHG 41: High voltage

This AHG was newly established in Oslo. A ›Call for experts‹ was made. At the TC 31 meeting in Oslo, the WG 22 was also assigned the task to develop proposals for the individual types of protection on how to include the tested products in dust layers at temperature tests according to IEC 60079. To date, such supplementary test specifications only exist for the types of protection ta (IEC 60079-31) and ma (IEC 60079-18). For example, IEC 60079-31 CDV 2. Ed. section 6.1.2 ›Thermal Tests‹, states that when determining the operating temperature, the test specimens for type of protection ta are to be completely embedded in a dust layer with 200 mm thickness on all sides. A maintenance team, to be headed by Dr. M. Thedens (Germany), was established for the new special type of protection standard IEC 60079-33 (type of protection ›s‹). The convenor of the MT 60079-15, A. Engler (USA), was assigned the task to make proposals on the modification of Standard IEC 60079-15 after a major portion of the original content had been incorporated in the corresponding type of protection standards as requirements for the products of the EPL Gc and Dc. IEC 60079–0: Explosive atmospheres - Equipment – General requirements The 6. edition of the basic standard was published in 2011. The stability date was given as 2015. It is expected that revision to the 7. edition can take place in 2014. The harmonisation of the European Standard EN

world-class Where safety knows no compromises _ R. STAHL sets new standards. As one of the leading suppliers of systems and components for hazardous areas, we offer the complete spectrum for the following fields: > Automation > Distribution and Control > Operating and Monitoring > Installation Equipment > Lighting > Alarm and Signalling. R. STAHL stands for modern explosion protection worldwide. With their great commitment, competent teams attend to the safety of people and facilities. 6400 you. We will gladly806 assist R. STAHL Middle East FZE, Dubai, U.A.E., Tel. + 971 4 8835855 or info@stahl.ae

Ex Standards

ex standards

60079-0:2011 is still delayed due to technical comments from various European national committees which were not admissible according to the statutes. To avoid such delays, the European national committees have agreed to cooperate better in future.

IEC 60079–1: Equipment protection by flameproof enclosures ›d‹

The FDIS of the 7. edition of the standard was published in July 2012. The main modifications to the 6. edition include: • Introduction of Equipment Protection Levels (EPL) ›da‹, ›db‹ and ›dc‹, • New options for bonded joints, • To avoid misuse, U-housings may in future only be marked in the housing interior, • Housings, where the joint dimensions differ from the standard values, must be marked, • Novel Multi Step Joints are now permissible. In this case there must be at least two reversals of the joint direction. • Random testing of pressure resistance is now

possible, if, as part of type testing, a test was passed at three-fold reference pressure. For EPL ›dc‹, the requirements for type of protection ›encapsulated switching device‹ from IEC 60079-15, were incorporated. A novelty was the rejection of the FDIS by the national committees, as negative votes are not issued under normal circumstances at such an advanced stage of standard preparation. The reason for rejection is the comprehensive editorial modification of the text by the IEC Secretariat without consultation of the MT. According to IEC rules this resulted in a downgrading to CD status. It is now being attempted to avoid technical modifications to the standard, so that it can pass through the standards process without further delays. IEC 60079-2: Equipment protection by pressurized enclosures ›p‹ The CDV of the 6. edition of the IEC 60079-2 has been published.. The main novelties compared to the 5. edition of the standard include: • Additional requirements for pressurized systems • Requirements for dust protection applications, • New definitions for px, py, pz, • Additional requirements for built-in batteries, • Modified testing requirements for fail-safe containments, • Modified testing requirements to limit the maximum pressure in the protective housing, • a second source for protective gas feed.

• Has a measuring range up to 30 meters. • Is virtually unaffected by fluctuating process conditions including dielectric, density, viscosity and specific gravity.

IEC 60079-7: Increased safety

eclipse.magnetrol.com • 971-4-6091735 • info@magnetrol.ae

After the 6. edition was published in 2011 and the stability date set at 2016, the MT has been collecting topics for the 7. edition since the meeting in Oslo which will be continued in March 2013 in Windsor.

• The pressure test to determine bubbles and cavities in the cast is being questioned.

IEC 60079-26: Equipment with equipment protection level (EPL) Ga

The comments on the CD of the 3. edition were discussed in April 2012 in Northbrook. The CDV version was published at the beginning of 2013. The stability date set is 2014.

IEC 60079-31: Equipment dust ignition protection by enclosure

The CDV was published in March 2012. The following modifications were made to the previous standard: • The safety margin for the maximum surface temperature was reduced from 20°K to 10°K. • The requirements for overpressure testing of ta devices were relaxed.

IEC 60079-25: Intrinsically safe electrical systems

The second edition of the standard was published in 2010. At present the topics for the 3. edition are being collected. The stability date has been set for 2015.

The topic ›Power-i‹ is now also gaining momentum in the standardisation process: after a so-called prepublication had already existed for the members of the working group as internal working paper, a technical specification was distributed in November 2012, which is to be discussed in 2013 in Windsor.

Work on the 5. edition of the standard commenced in October 2010 in Seattle. The CD was published in 100 | Automation INSIGHT! | decEMBER 2013

IEC 60079-11: Intrinsic safety

IEC 60079-5: Equipment protection by powder filling ›q‹

The previously known ›oil immersion‹ has become the ›liquid immersion‹, a first indicator of the fundamental review of the standard. The CD of the 4. edition was published in January 2012. As the stability date was set for 2016 here, ›freezing‹ will take one year longer than for powder filling.

• Takes the user interface experience to new levels of convenience and functionality.

There is general criticism among the experts to differentiate between requirements for indoor and outdoor use. This is regarded as being difficult to put into practice and would probably lead to uncertainty among operators and installers.

Since Seattle, an ad hoc working group of the subcommittee SC 31G has been working on modifications to the spark test apparatus. In particular, the cadmium disc to be replaced and an extension of testing options reached. The work will also be continued in Winsor.

IEC 60079-6: Equipment protection by liquid immersion ›o‹ • Has a superior signal-to-noise ratio.

Furthermore, two ad hoc working groups are working on the topics ›Modern light sources‹ and ›Requirements for EPL ›ec‹ products‹.

The following weak points are criticised by experts: • The requirements given in section 5.9 for housings are deemed insufficient. • According to section 7.11, signalling with a signal lamp is possible in case of overpressure failure. This is left to the judgement of the operator.

The CDV of the 4. edition was distributed in October 2012. As the stability date was set for 2015, publication of the FDIS needs to wait until 2015. This ›freezing‹ of the new standard publication is rather regrettable, as it contains a number of improvements useful in practice.

• Exhibits best-in-class accurate and reliable level measurement.

November 2012. The main modifications are as follows: • Introduction of the EPLs ›eb‹ and ›ec‹, • Requirements of IEC 60079-15 for ›na‹ are moved to part 7 under ›ec‹, • New requirements for inverter operation, adapted to the respective EPL, • Definition, that U-housings may only be marked internally.

PT 60079-39

IEC 60079-18: Equipment protection by encapsulation ›m‹

The CD of the 4. edition was published in June 2012. The CDV was prepared at the meeting in Oslo. As the stability date was set for 2015, there is still sufficient time to complete work on the new edition of the standard. This includes the following important modifications: • Monitoring equipment is only required to maintain the maximum permitted surface temperatures. • The temperatures for the temperature storage tests have been defined more precisely and simplified. december 2013 | Automation INSIGHT! | 101

Over

projects tracked 20,000 major in over

100 countries across13 major sectors

Customizable Dashboard

Project Overview

Advanced Search

KEY FEATURES • • • • • • • • • • • • • • • •

Project Scope and Background Track Project Schedules Key Personnel Details Track Entire Project Lifecycle Access Linked Projects Access Project Locations Advanced Search Features Favourites, Notes, Reminders Track Updates Customized Email Alerts Statistics, Analysis & Forecasting Data Download Project Values and Financing Global Network of Researchers Customized Research Modules Business Profile of Colleagues

NEW FEATURES Key Personnel

Bidders List

Market Forecast

Industry News

• Customizable Dashboard • Messaging/Sharing Projects Amongst Your Members Group • Stream Current Industry News Through Your Dashboard • Forecast Models by Feasibility & EPC Award Dates • Compare Contractor Workloads Against Each Other • 65 Levels of Key Personnel • Deeper Project Financing Data

Tel: +973 1740 5590 • Fax: +973 1740 5591 • info@dmsglobal.net www.dmsprojects.net

20,000 major projects tracked in over Over

100 countries across13 major sectors

DMS Projects tracks thousands of projects in over 100 countries across 13 major sectors, making the DMS Projects Matrix the most accurate, encompassing and extensive resource for companies looking for new business opportunities anywhere. DMS Projects brings to you the latest information about future, on-going, and completing projects. Having this information at your fingertips will enable you to make informed business development decisions to give you the edge that you need in today’s competitive marketplace.

REGIONS COVERED

• Asia Pacific • North America • China • Russia & CIS • Central America • South America • Europe • Sub-Saharan Africa • Indian Sub-Continent • Middle East & North Africa

SECTORS COVERED • • • • • • •

Construction Fertilizers Gas Industrial Infrastructure Mining Offshore

• • • • • •

Oil Petrochemicals Pipeline Power Refining Water

Tel: +973 1740 5590 • Fax: +973 1740 5591 • info@dmsglobal.net www.dmsprojects.net

project name:

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery Offsite Pipelines (Package 5) Name of Client:

Status:

Construction

Project Status Dec 2010

All American Consulting Group has been named as the contracts administrator by KBR.

Dec 2010

KBR has sub-contracted Abdulhadi & Al Moaibed Consulting & Design Engineers (AMCDE) for executing the vast majority of the FEED and detail design works.

Budget ($ US):

1,500,000,000

PMC:

KBR (Kellogg Brown & Root)

Aug 2010

Engineering works have started.

Main Contractors:

Multi Products

Main Contractor

Dayim Punj Lloyd

Facility Type:

Oil Pipeline

Location

Yanbu

Jul 2010

The EPC contract has been awarded to Dayim Punj Lloyd.

Jul 2010

Aramco decided to move ahead with the project alone and formed a new company known as the "Red Sea Refining Company" to execute the project.

Jul 2010

ConocoPhillips has announced its withdrawal from the project, citing changes in its development strategy. However, Saudi Aramco will still use its technology for the refinery.

Jun 2010

Under the terms of a corporate procurement agreement (CPA) signed with Saudi Aramco, Flowserve has received the final approval to supply pumps, valves and value-added services on the scheme. Flowserve expects to begin booking orders in late 2010.

Jan 2010

The client has received several bids that were re-sumbitted by the companies for the EPC contract.

Aug 2009

Kellogg Brown & Root (KBR) has been awarded the combined project management consultancy (PMC) and front end engineering and design (FEED) study contract.

Jul 2009

The scope of the project has been slightly altered as the client plans to add an aromatics unit at the refinery.

Jul 2009

Majority of the feedstock for the refinery will be sourced from the Manifa Arabian Heavy Crude Program, which is targeted to produce 90,0000 barrels per day (bpd) of Arabian Heavy Crude.

Jul 2009

Aramco Services Company has revealed plans to provide project liaison, engineering, logistics and administrative support to the team throughout the scheme.

Jul 2009

The following consultants have been appointed:

Project background The Red Sea Refining Company plans to develop the offsite pipelines at the Yanbu Export Refinery. The project, which will be in partnership with ConocoPhillips, will be the fifth package of the refinery. In May 2006, Saudi and ConocoPhillips signed a Memorandum of Understanding (MoU) to conduct a detailed evaluation for the proposed development of a 400,000 barrel per day (bpd), full conversion refinery in Yanbu. The proposed refinery will be designed to process Arabian Heavy Crude and produce high-quality, ultra-low sulfur refined products that meet current and future U.S. and European product specifications. The project is one of two new facilities that will substantially increase the Kingdom’s supply of petroleum products to the international market. The combined output from the two new refineries will help meet increasing demand from the world’s largest consuming countries and use Saudi Arabia’s production fields. They also will help alleviate the shortage of refining capacity worldwide, particularly of heavy-grade crude oils.

Project Status Nov 2013

The sub-contract for civil works has been awarded to Abdullah Faleh Al Dossary & Partner Company.

Jul 2013

Construction works are expected to be completed in June 2014, with start-up operations set to begin in September 2014, while the first commercial shipment of refined products will happen in the fourth quarter 2014.

Apr 2013

The joint venture of SNC Lavalin and Fayez Engineering has bagged a General Engineering Services (GES) contract at the scheme. The two year contract will see the JV companies carry out a range of engineering services.

Dec 2012

The client has revealed that construction of its offsite pipelines is moving as per schedule.

May 2012

Jacobs Zate has been awarded a sub-contract to support the engineering and procurement as well as validate the FEED and detailed design of the scheme.

May 2012

Construction of the pipeline has commenced. It is expected to be completed in January 2014.

Feb 2012

Site mobilization and engineering works are in progress.

Jan 2012 Mar 2011

WorleyParsons: They will conduct the feasibility studies White & Case: They will be in-charge of the legal team Fugro Consultants Incorporated: They will handle all geo-technical engineering services Jul 2009

Citibank and Riyad Bank have been appointed as financial advisors on the scheme.

Jun 2009

ITB for the EPC contract has been re-issued by the client.

Apr 2009

Pre-qualification applications for the EPC contract were submitted by several local as well as international companies.

Saudi Aramco and Sinopec signs an official agreement to construct the offsite pipelines at the Yanbu export refinery.

Nov 2008

Aramco and ConocoPhillips announced their decision to halt the bidding process for the EPC contract.

Saudi Aramco and China Petroleum & Chemical Corporation (Sinopec) signs a joint venture agreement to expand the refinery. The deal will give Saudi Aramco a 62.5 per cent equity stake in the project, and Sinopec the remaining 37.5 per cent.

Aug 2008

The client has issued invitations to bid (ITB) for the engineering, procurement and construction (EPC) contract. The initial deadline to submit commercial and technical bids for the EPC contract is 15 November 2008.

104 | Automation INSIGHT! | decEMBER 2013

december 2013 | Automation INSIGHT! | 105

Project Scope

Saudi Arabia

The scope of work involves construction of the offsite pipelines including: • Onshore crude oil pipeline (30 inch x 6.75 Km) • Onshore Isobutene / butane pipeline (6 inch x 4.50 Km) • Pipelines for various hydrocarbons (12inch/24inch/36 inch x 2 Km) • Other utility pipelines for processing potable water, sewer and fuel gas supply (6inch/16inch/20 inch) • Custody metering system for butane and propane • Civil, electrical and field instrumentation works • Laying of steel and plastic pipeline • Utility services • Associated custody metering systems • Electrical, instrumentation and control systems Dayim Punj Lloyd Construction and Contracting Company’s scope of work includes EPC of the following: • Steel pipelines for crude oil • Gasoline • Diesel • Isobutene • Butane • Benzene • Fuel gas supply • Reinforced Thermosetting Plastic seawater supply and return pipeline (114 inch/ 134inch x 8.4 Km)

Project Schedule

Project Finance Saudi Aramco and Sinopec (China Petroleum & Chemical Corporation) have formed the Red Sea Refining Company. They will manage the project under the name of Yanbu Saudi Aramco Sinopec Refining Company Limited (Yasref). The shares of Yasref are as follows: • Saudi Aramco: 62.5 per cent • Sinopec: 37.5 per cent Citibank and Riyad bank are the financial advisors on the scheme. In August 2006, Citibank and Riyad Bank were awarded the advisory mandate. Third party sources indicate that Yanbu export refinery may cost 20 to 25 per cent less to build than an almost identical project that Saudi Aramco is building at the Gulf coast. Hoever, the cost of the EPC contracts for the refineries do not reflect the overall budget value of each project. Normally, they represent around 75 per cent of the overall cost of the scheme, with financing, advisery, design, procurement and management costs adding the remaining 25 per cent.

Facility

Budget ($ US)

Status

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery _ Relocation of Natural Gas to Liquids (NGL) Pipeline

Gas

50000000

Construction

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery Offsite Pipelines (Package 5)

Multi Products

1500000000

Construction

Sadara Chemical Company - Jubail Integrated Refining & Petrochemicals Project (Overview)

Refinery

20000000000

Engineering & Procurement

Farabi Petrochemicals Company _ Jizan Petrochemicals Plant

Linear Alkyl Benzene (LAB)

700000000

Feasibility Study

Saudi ARAMCO - Expansion of Khurais Oilfield

Oil & Gas Field

3000000000

FEED

Saudi Aramco Total Refinery and Petrochemical Company (Satorp) - Jubail Export Refinery

Refinery

10000000000

Construction

Kingdom Holding - Emaar Properties - Kingdom Tower or Mile High Tower

Mixed-Use Development

1300000000

Construction

Al Khafji Joint Operations (KJO) - NGL and Export Terminal Facilities

Natural Gas Liquefaction (NGL)

50000000

Construction

Saudi Arabian Fertiliser Company (Safco) - Fifth Urea Plant

Urea

550000000

Engineering & Procurement

Maaden - Sabic - Mosaic - Waad Al Shamaal Mining City - Phosphoric Acid Plant

Phosphoric Acid

400000000

EPC ITB

Sadara Chemical Company - Jubail Petrochemicals Complex - High Pressure Low Density Polyethylene (HP-LDPE) Plant

Low Density Polyethylene (LDPE)

400000000

Construction

Saudi Binladin Group - Saudi Oger - Jabal Omar Development Company - Real Estate Project

Mixed-Use Development

2700000000

Construction

Sadara Chemical Company - Jubail Petrochemicals Complex - Aromatics Complex

Petrochemical Complex

300000000

Construction

IDEA Soda Ash & Calcium Chloride Company (ISACC) - Soda Ash and Calcium Chloride Complex

Detergents

300000000

EPC ITB

Feasibility Study

2Q-2008

Sabic Terminal Services Company (Sabtank) _ Vopak _ Expansion of Tank Farm Facilities at Jubail Industrial Port

Oil Storage Tanks

450000000

Engineering & Procurement

EPC ITB

3Q-2008

Royal Commission for Jubail & Yanbu (RCJY) _ Ras Al Khair Industrial Wastewater Treatment Plant (IWTP)

Waste Water Treatment

80000000

EPC ITB

FEED

3Q-2009

Maaden - Sabic - Mosaic - Waad Al Shamaal Mining City - Sulphuric Acid Plant & Power Plant

Sulphuric Acid

1500000000

EPC ITB

PMC

3Q-2009

Saudi Aramco - Ras Tanura Refinery - Aromatics Unit

Aromatics

1000000000

EPC ITB

Saudi Aramco - Ras Tanura Refinery - Clean Fuels Package

Aromatics

1000000000

EPC ITB

EPC

3Q-2010

Maaden - Sabic - Mosaic - Waad Al Shamaal Mining City (Package 2) - DAP / NPK / BOP

Petrochemical Plant

750000000

EPC ITB

Construction

2Q-2012

Maaden - Gold Processing Plant

Gold Refinery

300000000

Engineering & Procurement

Completed

1Q-2014

AJOC - KJO - Expansion of Khafji Crude Production Facilities (Hout Field Onshore & Offshore)

Oil Production

1522000000

Construction

Maaden - Alcoa - Al Zabirah/Al Baitha Bauxite Mine

Bauxite

200000000

Construction

Makkah-Madinah Rail Link - Haramain High Speed Rail Link (Overview)

Railway

12000000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Ethylene Oxide Plant

Ethylene Oxide

600000000

Construction

Saudi Aramco - Midyan Gas Processing Plant

Gas Processing

800000000

Construction

* Information provided by DMS Projects Matrix. For more details, please contact us T:+973 1740 5590, F: +973 1740 5591, Email: info@dmsglobal.net Log onto www.DM SGLOBAL.net

106 | Automation INSIGHT! | decEMBER 2013

Project

Idea International - Yanbu Polysilicon Plant & Solar Wafer Production Plant

Polymers

1100000000

EPC ITB

Saudi Electricity Company (SEC) - Qurayyah Independent Power Plant (IPP) {Overview}

Independent Power Plant (IPP)

5000000000

Construction

Saudi Electricity Company (SEC) - Rabigh 2 Independent Power Plant (IPP)

Independent Power Plant (IPP)

1800000000

Engineering & Procurement

december 2013 | Automation INSIGHT! | 107

Saudi Arabia

Project

Facility

Budget ($ US)

Status

Project

Facility

Budget ($ US)

Status

Ministry of Transportat _ Dammam Light Rail and Bus Network (Dammam Metro)

Railway

7500000000

Feasibility Study

Kemya Elastomer Plant - Halobutyl Rubber Plant (HRP)

Petrochemical Plant

600000000

Engineering & Procurement

Saudi Electricity Company (SEC) - Rabigh Steam Independent Power Plant (IPP)

Independent Power Plant (IPP)

180000000

Design

Arabian Amines Company (AAC) - Morpholine and Diglycolamine (DGA) Plant

DGA

300000000

EPC ITB

National Titanium Dioxide Company (NTDC) - Cristal Global - AC Arc Ilmenite Smelting Plant

Utilities

500000000

Engineering & Procurement

Saudi Aramco - Fadhili Gas Plant

Gas Field

1000000000

FEED

Basic Chemical Industries Company (BCI) - CP Kelco - Xanthan Gum Facility

Propylene

Saudi Aramco - Jizan Export Refinery (Overview)

Refinery

7000000000

Saudi Aramco - Jizan Export Refinery _ Sour Water Stripper & Amine Regeneration Unit

Refinery

Saudi Aramco - Jizan Export Refinery - Diesel Hydro-Treater Unit

Cayan Investment & Development Company (CIDC) - Lamar Towers

Mixed-Use Development

532000000

Construction

Kayan Petrochemical Company (KPC) - Ultra High Molecular Weight Polyethylene Plant

Polyethylene

200000000

FEED

Sadara Chemical Company - Jubail Petrochemicals Complex - Port Tank Farm

Petrochemical Complex

400000000

Engineering & Procurement

Wafra Joint Operations Company _ Wafra Heavy Oil Field (Overview)

Steam Injection

800000000

Engineering & Procurement

500000000

Construction

Ministry of Health (MOH) - King Abdullah Medical City

Medical/Health Facilities/Spa

300000000

EPC ITB

Maaden - Phosphate Mine - Al Khabra Deposit

Phosphate

6000000000

FEED

Diesel Hydro Desulphurisation (DHDS)

220000000

Engineering & Procurement

Saudi Aramco - Dow - Ras Tanura Gas Plant (Overview)

Gas Field

4000000000

EPC ITB

Saudi Aramco - Jizan Export Refinery - Marine Terminal Facilities

Marine Terminal

500000000

Construction

Sabic _ Shell - Sadaf Polyurethane Plant

Styrene

300000000

Feasibility Study

Saudi Railway Organization (SRO) - LandBridge Rail Link

Railway

5000000000

PMC

Saudi Aramco - Jizan Export Refinery _ Tank Farms

Oil Storage Tanks

1000000000

Construction

Petro Rabigh Refinery & Petrochemical Complex Expansion - Phase 2 (Overview)

Aromatics

5000000000

Engineering & Procurement

Saudi Aramco - Jizan Export Refinery - Site Preparation

Oil Production

1000000000

Engineering & Procurement

Petro Rabigh Refinery & Petrochemical Complex Expansion - Phase 2 - Utilities and Offsites (UO1)

Offsites & Utilities

5000000000

Engineering & Procurement

Saudi Electricity Company (SEC) - Jeddah South Thermal Power Plant

Power Plant

5000000000

Construction

Feasibility Study

MAADEN - Ras Al Khair Aluminium Smelter

Aluminium Smelter

7000000000

Construction

Petrochemical Plant

200000000

Engineering & Procurement

Petro Rabigh Refinery & Petrochemical Complex Expansion - Phase 2 - Tank Farm Package (UO2) & Common Facilities (UO3)

Refinery

500000000

Construction

Solvay - Sadara Chemical Company - Hydrogen Peroxide Plant

Saudi Japanese Acrylonitrile Company (SHROUQ) - Acrylonitrile and Sodium Cyanide Complex

Aromatics

250000000

Feasibility Study

Maaden - Sabic - Mosaic - Waad Al Shamaal Mining City (Package 1) Ammonia Plant

Petrochemical Plant

850000000

Engineering & Procurement

Saudi Aramco - Integrated Gasification Combined Cycle (IGCC) Power Plant

Power Plant

2400000000

EPC ITB

Al Omran Cement Company - Taif Cement Plant

Cement

350000000

EPC ITB

Marafiq - Jubail Sea Water Reverse Osmosis 4

Water Treatment

250000000

Engineering & Procurement

Maaden - Sabic - Mosaic - Waad Al Shamaal Mining City (Overview)

Phosphate

6900000000

Engineering & Procurement

Sabic - Celanese Corporation - National Methanol Company (Ibn Sina) Polyacetal Plant Factory

Offsites & Utilities

400000000

Engineering & Procurement

LUBEREF - Lubricants Refinery Expansion

Lube Oil

1000000000

Engineering & Procurement

Saudi International Petrochemical Company (Sipchem) _ Zero Liquid Discharge Waste Water System

Waste Water Treatment

Unknown

Feasibility Study

SAUDI ARAMCO - BAPCO - New Arabia Pipeline

Oil

350000000

FEED

Sadara Chemical Company - Jubail Petrochemicals Complex - Ethylene Oxide Derivatives (EOD) Unit

Ethylene Oxide

350000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Cycrogenic Tank Farm

Petrochemical Complex

500000000

Construction

Sadara Chemical Company - Jubail Petrochemicals Complex - Chlorine Plant

Petrochemical Complex

500000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Aniline Formalin and Dinitroluene (DNT) Nitric Facilities Package

Formaldehyde

500000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Acrylic Acid Monomers Complex & Plastics Plant

Acrylic Monomers

1700000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Propylene Oxide (PO) Facility

Propylene

500000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Polyethylene Package

Polyethylene

1300000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Polyethylene Oxide Diacrylate (POD) Plant

Polyethylene

300000000

Engineering & Procurement

SABIC - Mitsubishi Rayon - Alpha 2 - Petrochemical Plants

Dimethyl Ether (DME)

500000000

EPC ITB

Sadara Chemical Company - Jubail Petrochemicals Complex - Toluene Di-Isocyanate (TDI) Production Facility

Toluene Di-Isocyanate

1000000000

Engineering & Procurement

Saudi Aramco - Abqaiq Greenfield Gas Fired Electricity and Steam Plant

Gas Fired Power Station

400000000

Engineering & Procurement

Saudi Aramco - Hawiyah Greenfield Gas Fired Electricity and Steam Plant

Gas Fired Power Station

220000000

Engineering & Procurement

Sabic - Hadeed Steel Plant Debottlenecking

Steel Plant

150000000

Construction

SWCC - Marafiq - Yanbu Power and Desalination Plant (Phase 3) - Yanbu 3 IWPP

IPWP (Independent Power & Water Project)

3500000000

Engineering & Procurement

Saudi Electricity Company (SEC) - Shuqaiq Steam Power Plant

Power Plant

600000000

Engineering & Procurement

Saudi Aramco - Jizan Export Refinery - Naphtha Hydrotreater Complex

Hydrotreating

500000000

Engineering & Procurement

Saudi Aramco - Jizan Export Refinery _ Utilities Package

Offsites & Utilities

1000000000

Engineering & Procurement

Saudi Aramco - Jizan Export Refinery - Hydrocracker Unit

Hydrocracker

250000000

Engineering & Procurement

Saudi Aramco - Jizan Export Refinery - Crude Distillation Unit/Vacuum Distillation Unit, Flare & Pipe Rack Complex

Refinery

500000000

Engineering & Procurement

National Water Company (NWC) - Northern & Eastern Manfouha Water Treatment Plant Expansion

Waste Water Treatment

80000000

EPC ITB

108 | Automation INSIGHT! | decEMBER 2013

december 2013 | Automation INSIGHT! | 109

Saudi Arabia

Project

Facility

Budget ($ US)

Status

Project

Facility

Budget ($ US)

Sadara Chemical Company - Jubail Petrochemicals Complex - Oxygen Plant

Petrochemical Complex

380000000

Engineering & Procurement

National Industrialization Company (TASNEE) _ Metals Smelter Complex

Zinc

1000000000

Feasibility Study

Kemya Elastomer Plant _ Carbon Black Plant

Carbon Black

300000000

Engineering & Procurement

Kemya Elastomer Plant - Ethylene Propylene Diene Monomer (EPDM) Plant

Ethylene

600000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Mixed Feed Cracker

Petrochemical Complex

2000000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Methyl-Nnitrosobenzamide (MNB) Package

Petrochemical Plant

500000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Hydrogen Plant

Petrochemical Complex

380000000

Engineering & Procurement

Saudi Electricity Company (SEC) - Power Plant Conversion (PP10) - (Blocks A1, A2, B1, B2 and C1)

Combined Cycle

1430000000

Construction

Saudi Electricity Company (SEC) - Power Plant 14 (PP14)

Combined Cycle

1760000000

Feasibility Study

Saudi Electricity Company (SEC) - Power Plant 12 (PP12)

Power Plant

2000000000

Construction

Saudi Electricity Company (SEC) - Power Plant 10 (PP10) {Overview}

Power Grid

3000000000

Engineering & Procurement

Saudi Electricity Company (SEC) - Power Plant 13 (PP13)

Combined Cycle

2000000000

Feasibility Study

Jubail Chemicals Storage and Services Company (JCSSC) - Storage, Handling & Shipping Terminal at King Fahd Industrial Port

Marine Terminal

400000000

Saudi Aramco - King Abdullah Petroleum Studies & Research Centre (Kapsarc)

Education/Training Facilities

Saudi Aramco - Shaybah NGL - Recovery Unit (Overview)

Status

Makkah Municipality _ Solar Power Plant

Solar Power

640000000

EPC ITB

Saudi Electricity Company (SEC) - Shuaibah Power Plant II

Combined Cycle

1400000000

Construction

MAADEN - Ras Al Khair Alumina Refinery

Aluminium Smelter

1000000000

Construction

Al Jubail Petrochemical Complex (Kemya) - Elastomer Plant (Overview)

Carbon Black

5000000000

EPC ITB

Petro Rabigh Refinery & Petrochemical Complex Expansion - Phase 2 _ MTBE Plant

MTBE

500000000

Construction

National Water Company (NWC) - Sewage Treatment Plant at King Abdul Aziz International Airport

Sewerage Treatment

273000000

EPC ITB

Saudi Electricity Company (SEC) _ Al-Kharj 2 Substation

Substations

150000000

Engineering & Procurement

Kemya Elastomer Plant - Polybutadiene Rubber (PBR) Plant

Petrochemical Plant

600000000

300000000

Engineering & Procurement

Kemya Elastomer Plant - Offsites and Utilities

Offsites & Utilities

500000000

Natural Gas Liquefaction (NGL)

6000000000

Construction

Engineering & Procurement

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery _ Storage Tanks/Tank Farm (Package 6)

Oil Storage Tanks

1000000000

Construction

Kemya Elastomer Plant - Methyl Tertiary Butyl Ether (MTBE) Plant

MTBE

1000000000

Construction

Saudi Aramco - Hasbah Offshore Development Program - Gas Processing Plant

Gas Processing

1500000000

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery Hydrocracker Facility (Package 4)

Hydrocracker

1200000000

Construction

Engineering & Procurement

SAUDI ARAMCO - Arabiyah and Hasbah Gas Field Development (Overview)

Gas Field Development

3000000000

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery Coker Unit (Package 1)

Petroleum Coke

1200000000

Engineering & Procurement

Industrial Park

2600000000

Saudi Aramco - Dow - Ras Tanura Gas Plant - Ethylene Cracker and TDI Units

Gas Processing

500000000

Construction

Public Pension Authority (PPA) - Information Technology and Communications Complex (ITCC) {Overview}

Engineering & Procurement

National Water Company (NWC) - Riyadh Sewerage Network _ Phase 2 (Al Monsaiah Quarter)

Sewerage Treatment

400000000

EPC ITB

Saudi Kayan - Saudi Acrylic Acid Company (SAAC) - Sadara Chemical Company National Industrialization Company (Tasnee) - N-Butanol Plant

Butanol

500000000

Engineering & Procurement

Saudi International Petrochemical Company (Sipchem) Chemicals Company Polybutylene Terephthalate (PBT) Plant

Polybutylene Terephthalate (PBT)

165000000

Engineering & Procurement

Saudi Aramco - Liquefied Natural Gas (LNG) Receiving Terminal

Liquefied Natural Gas (LNG)

1000000000

Feasibility Study

Unleaded Gasoline

2300000000

Construction

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery Crude Block Facility (Package 2)

Refinery

1000000000

Construction

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery Gasoline Distiller Block (Package 3) SAUDI ARAMCO - Carbon Dioxide Injection Plant - Uthmaniyah Field

Carbon Dioxide

100000000

Yanbu Aramco Sinopec Refining Company (YASREF) - Yanbu Export Refinery (Overview)

Refinery

13000000000

Engineering & Procurement

Atoun Steel Industry Company - Yanbu 2 Steel Plant

Steel Plant

267000000

Construction

Petrokemya - Acrylonitrile Butadiene Styrene (ABS) Plant

Styrene

561000000

Construction

Saudi Aramco - Jizan Export Refinery - Power Plant Interconnection

Power Plant

75000000

Feasibility Study

Saudi Aramco - Bulk Storage Terminal

Floating Storage and Offloading (FSO)

600000000

FEED

MAADEN - Development Overview

Petrochemical Complex

5000000000

Kuwait Gulf Oil Company (KGOC) - Gas and Condensate Export System

Condensate Refinery

2000000000

Construction

Engineering & Procurement

Sabic - ExxonMobil Chemical Company - Kemya - Yanpet - Synthetic Rubber Plant

Butadiene

5000000000

Construction

Grain Silos & Flour Mills Organization (GSFMO) - Jizan Grain Silos _ Wheat Silos Plant

Food Processing Plant

99700000

Engineering & Procurement

Polysilicon Technology Company (PTC) - Polysilicon Manufacturing Plant

Polysilicon

1400000000

Engineering & Procurement

Saudi Aramco - Wasit Gas Field Development (Overview)

Gas Field Development

6000000000

Construction

Sadara Chemical Company - Jubail Petrochemicals Complex - Refinery Tank Farm Package

Oil Storage Tanks

500000000

Construction

Sadara Chemical Company - Jubail Petrochemicals Complex - Polymeric Methylene Diphenyl Disocyanate (PMD) Facility

Polyolefins

500000000

Engineering & Procurement

Sadara Chemical Company - Jubail Petrochemicals Complex - Offsites & Utilities

Offsites & Utilities

1650000000

Construction

110 | Automation INSIGHT! | decEMBER 2013

Grain Silos & Flour Mills Organization (GSFMO) - Jizan Grain Silos (Overview)

Food Processing Plant

150000000

Construction

Grain Silos & Flour Mills Organization (GSFMO) - Jizan Grain Silos - Flour Mill

Food Processing Plant

50000000

Construction

Sahara & Maaden Petrochemicals Company (Samapco) - Ethylene Dichloride (EDC) and Acrylic Complexes

Ethylene

750000000

Construction

SAMREF - Yanbu Oil Refinery Revamp - Clean Fuels Project (Overview)

Refinery

2000000000

Engineering & Procurement

Saudi Aramco - Wasit Gas Development - Onshore Facilities - Sulphur Recovery Units

Sulphur Recovery

250000000

Engineering & Procurement

Saudi Aramco - Wasit Gas Development - Onshore Facilities - NGL Fractionation Plant

Natural Gas Liquefaction (NGL)

150000000

Engineering & Procurement

december 2013 | Automation INSIGHT! | 111

Saudi Arabia

Project

Facility

Budget ($ US)

Status

Project

Facility

Budget ($ US)

Status

Saudi Aramco - Wasit Gas Development - Onshore Facilities - Gas Processing Unit

Gas Processing

200000000

Engineering & Procurement

National Water Company (NWC) - Riyadh Water Treatment Plants, Drilling of Deep Wells & Water Storage

Waste Water Treatment

60000000

Engineering & Procurement

Saudi Aramco - Wasit Gas Development - Industrial Support Facilities

Offsites & Utilities

100000000

Engineering & Procurement

SAMREF - Yanbu Oil Refinery Revamp - Clean Fuels Project - Process Units Package (Phase 1)

Oil Processing Facility

1500000000

Engineering & Procurement

Saudi Aramco - Wasit Gas Development - Arabiyah Offshore Facilities

Offshore Platform

100000000

Construction

Rafal Real Estate Development Company - Burj Rafal

Mixed-Use Development

800000000

Construction

Saudi Electricity Company (SEC) _ High Voltage District Current (HVDC) Link _ Riyadh to Makkah

Power Transmission Lines

100000000

Engineering & Procurement

Saudi Electricity Company (SEC) _ Yanbu to Umluj Overhead Transmission Line

Power Transmission Lines

84300000

Engineering & Procurement

Saudi Electricity Company (SEC) _ Al Madain Substation

Substations

111000000

Engineering & Procurement

Saudi Aramco - Shale Gas Production

Shale Gas

Unknown

Feasibility Study

Public Pension Association (PPA) - King Abdullah Financial District (KAFD)

Mixed-Use Development

7800000000

Engineering & Procurement

Saudi Electricity Company (SEC) - Rabigh VI Power Plant

Power Plant

4000000000

Construction

National Water Company (NWC) - Privatization of Water and Wastewater Network

Waste Water Treatment

5600000000

Engineering & Procurement

Minerals Railway - Al Zabirah to Al Jalamid Railway Project

Railway

280000000

Engineering & Procurement

General Aviation Civil Authority (GACA) - Arar Domestic Airport Expansion

Airport

100000000

EPC ITB

Saudi Electricity Company (SEC) _ Al Lith Substation

Substations

94000000

Engineering & Procurement

Saudi Electricity Company (SEC) - 3,600 MW Thermal Power Plant

Thermal Power Station

3000000000

EPC ITB

Saudi Aramco - Riyadh Refinery - Clean Transportation Fuel

Isomerisation

2500000000

Engineering & Procurement

Saline Water Conversion Corporation (SWCC) - Dow Chemical Company - Pilot Water Treatment Plant

Water Treatment

60000000

Feasibility Study

Saudi Aramco - Safaniyah Oil Field (Phase 2)

Oil & Gas Field

500000000

EPC ITB

Jeddah Municipality - King Abdul Aziz Airport Expansion - Floodwater Prevention Scheme

Canal

903000000

Engineering & Procurement

Damac Properties _ Riyadh Tower

Mixed-Use Development

200000000

Design

Ministry of Transport & Communication - GCC Railway Network

Railway

12000000000

Design

General Aviation Civil Authority (GACA) _ King Khalid International Airport _Terminal 5 Building

Airport

600000000

Engineering & Procurement

Al Zamil Group - Chemtura Corporation - Jubail Metal Alkyls Plant

Ethylene

150000000

Engineering & Procurement

SAUDI ARAMCO - King Abdulaziz Centre for Knowledge & Culture

Theatre/Entertainment/Leisure Facilities

300000000

Construction

Saudi Railway Organization (SRO) _ Dammam to Riyadh Dual Railway (Overview)

Railway

122000000

EPC ITB

Jubail Chemicals Storage & Services Company - Petrochemicals Quay 2 (PCQ 2)

Petrochemical Plant

4500000000

Engineering & Procurement

Ministry of Health (MOH) - Expansion of the King Faisal Specialist Hospital and Research Centre

Medical/Health Facilities/Spa

354000000

Engineering & Procurement

NCP - Petrochem - Petrochemical Complex

Petrochemical Complex

4000000000

Engineering & Procurement

Saudi Aramco - Upgrade of Waste Water Treatment Facilities - Jeddah Refinery

Waste Water Treatment

100000000

Engineering & Procurement

King Abdullah Financial District - Capital Markets Authority Tower

Office Buildings

300000000

Construction

Riyadh Municipality - King Abdullah International Gardens

Theatre/Entertainment/Leisure Facilities

200000000

EPC ITB

Ministry of Higher Education - Najran University - Medical College for Women

Medical/Health Facilities/Spa

48000000

Engineering & Procurement

Ministry of Higher Education - Najran University Hospital

Medical/Health Facilities/Spa

150000000

Engineering & Procurement

Alargan Homes Company - Al Suhoul - Phase 1 Contract 1

Residential Development

50000000

Construction

Alargan Homes Company - Al Suhoul - Phase 1 Contract 2

Residential Development

50000000

Construction

National Water Company (NWC) - Wassia Water Treatment Plant _ Package 2

Water Treatment

150000000

EPC ITB

Ministry of Housing _ Housing Programme

Residential Development

67000000000

EPC ITB

Saudi Arabian General Investment Authority (SAGIA) - Pfizer - Pharmaceutical Manufacturing Plant at King Abdullah Economic City (KAEC)

Medical/Health Facilities/Spa

400000000

Feasibility Study

Ministry of Transport - Jeddah Ring Road Scheme (Phase 3)

Roads

61000000

Engineering & Procurement

General Aviation Civil Authority (GACA) - Prince Mohammed Bin Abdulaziz Airport Expansion

Airport

1000000000

Engineering & Procurement

Ministry of Health (MOH) - King Fahad Medical City Development - Research Laboratory and Consultant Offices

Medical/Health Facilities/Spa

200000000

Engineering & Procurement

Ministry of Health (MOH) - King Fahad Medical City Development Neuroscience Center

Medical/Health Facilities/Spa

290000000

Engineering & Procurement

Ministry of Health (MOH) - King Fahad Medical City Development - Central Services Building

Medical/Health Facilities/Spa

80000000

Engineering & Procurement

Ministry of Health (MOH) - King Fahad Medical City Development - Cancer Center

Medical/Health Facilities/Spa

370000000

Engineering & Procurement

Ministry of Health (MOH) - King Fahad Medical City Development (Overview)

Medical/Health Facilities/Spa

950000000

Engineering & Procurement

National Water Company (NWC) - Wassia Water Treatment Plant

Water Treatment

350000000

EPC ITB

National Water Company (NWC) - Wassia Water Treatment Plant _ Package 3

Water Treatment

100000000

EPC ITB

Ministry of Education - Imam Mohammed bin Saud Islamic University

Mixed-Use Development

400000000

EPC ITB

National Water Company (NWC) - Wassia Water Treatment Plant _ Package 4

Water Treatment

500000000

EPC ITB

Nuclear Power Station

7000000000

Feasibility Study

Power Transmission Lines

62600000

Engineering & Procurement

National Water Company (NWC) - Wassia Water Treatment Plant _ Package 1

Water Treatment

100000000

EPC ITB

CONSTRUCTION - King Abdullah City for Atomic and Renewable Energy (Kacare)

Saudi Global Ports Authority (SPA) - King Abdul Aziz Port - Container Terminal

Port

533000000

Construction

Saudi Electricity Company (SEC) - Double Circuit Overhead Transmission Lines

National Titanium Dioxide Company (NTDC) - High Pressure Oxidation Line (HPOL)

Offsites & Utilities

250000000

Engineering & Procurement

Ministry of Transport - Jeddah Ring Road Scheme (Phase 4)

Roads

66000000

Engineering & Procurement

Saudi Electricity Company (SEC) - Muhayil West Substation

Substations

117000000

Construction

112 | Automation INSIGHT! | decEMBER 2013

* Information provided by DMS Projects Matrix. For more details, please contact us T:+973 1740 5590, F: +973 1740 5591, Email: info@dmsglobal.net Log onto www.DM SGLOBAL.net december 2013 | Automation INSIGHT! | 113

Automation INSIGHT!

CIRCULATION:

5000 Copies

Outside Back Cover 200x279mm (trim) 206x285mm (bleed)

$7,500

Inside Front Cover $6,000 Inside Back Cover $6,000 Full Page $4,000

Double Page Spread 400x279mm (trim) 406x285mm (bleed)

$5,000

* And each additional page $1000 per page

Automation Insight!

CONTENTS

• • • • • • • • • • • • • • • •

DMS Analytic Company News Event Paparazzi Industrial Automation and Control Control System Cyber Security Wireless and Industrial Communications Functional Safety and SIS Asset Performance and Productivity Enhancements Custody Measurement Process Analyzers Advanced Applications Technology and Implementation Installation, Operation and Maintenance Issues Ex Standards Project Feature Project Listings

Your equipment isn’t the only thing operating under pressure You’re under more pressure than ever to increase production and commission new facilities, all while dealing with a shortage of skilled manpower. SKF can help. With over 80 years of experience with refineries worldwide, we provide a single source for a range of integrated solutions designed to extend service life and improve reliability of turbines, pumps, motors, fans, compressors, and other equipment critical to your operation.

1/2 Page Horizontal 190mm x 135mm $2,000

1/2 Page Vertical 95mm x 270mm $2,000

1/3 Page Horizontal 190mm x 90mm $1,500

) 1/3 Page Vertical 65mm x 270mm $1,500

1/4 Page 95mm x 135mm $1,000

All artwork to be at least 300dpi in Jpeg, PDF, EPS or Tiff format CMYK with bleed and sent directly to the production designer: Tracy Gutierrez, email: tgutierrez@dmsglobal.net

SKF helped a refinery redefine its maintenance strategy for mechanical, electrical, and static equipment. The plant was able to cut maintenance costs by four million euros per year, and achieved a 2% increase in availability.

With approximately 10,000 copies per issue focussing on the main oil and gas events taking place each quarter along with the circulation from our project database your visibility in the market will be guaranteed. Targeting the main EPC’S, top oil companies, and major players in the region AUTOMATION INSIGHT! will help deliver your advertising message to a wide and valuable audience.

Rebecca Thompson Marketing Manager

GLOBAL

114 | Automation INSIGHT! | decEMBER 2013

M: (+971) 50 181 9764 E: rthompson@dmsglobal.net

www.dmsglobal.net

To find out more about how we can help you meet your challenges, visit us at our booth to discover the latest innovations and get a preview of the future SKF Solution Factory for the Kingdom of Saudi Arabia.

Please visit us at booth D3!

Ignacio Alonso Regional Manager - Europe M: (+34) 622 697128 (+39) 328 9675433 E: ialonso@dmsglobal.net

Our portfolio is designed to meet the ever growing industry needs for reliability and safety. Solutions that range from bearing upgrades to highly effective asset management approaches, and from automatic lubrication systems to the industry’s leading condition monitoring systems, both handheld and online.