Automation INSIGHT!
ASSET PERFORMANCE AND PRODUCTIVITY ENHANCEMENTS Performance Qualifiers
INTERVIEW TELINSTRA: Ajay Menon
INSIGHT! ANALYTIC
Quarterly Market Analysis SEPTEMBER 2015
PROCESS ANALYZERS
Moisture Measurement Problem in Refinery Catalytic Reformer Operations – solved!
ESSENTIALS OF THE CONNECTED ENTERPRISE
Rockwell Automation
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automation INSIGHT!
FIRST WORD aSSET PERfoRMancE and PRoducTiViTy EnhancEMEnTS Performance Qualifiers
inTERViEW TElinSTRa: Ajay Menon
inSighT! analyTic
Quarterly Market Analysis
PRocESS analyZERS
Moisture Measurement Problem in Refinery Catalytic Reformer Operations – solved!
ESSEnTialS of ThE connEcTEd EnTERPRiSE
Rockwell Automation
SEPTEMBER 2015
COVER: Yahya Darwish, SalesDirector - KSA Rockwell Automation Automation Insight! September 2015 Vol. 3 Issue 2 PUBLISHED BY Data Media Systems (for private distribution) President & CEO Mohammed Loch mloch@dmsglobal.net Administration Manager Sara Loch sloch@dmsglobal.net Editor-in-Chief Hugh Wingrove hughwingrove@hotmail.com Editoral Designer Tracy Gutierrez tgutierrez@dmsglobal.net
Although all efforts to ensure accurate reporting are taken, some errors may occur. The views and opinions herein are not those of the Publishers. All Rights reserved. For any suggestions and questions about AUTOMATION INSIGHT! please write to: insight@dmsglobal.net
CONTENTS: 3 4-12 14
First Word Analytic Reports Company News Post Show Report
16-17
• Automation taking important role in
18-19
• The importance of automation and a
20
• Moxa and Telinstra FZCO announce regional
21 22-24 26-31
• PlantPAx from Rockwell Automation
32-34 36-37 40-43 46-47
• Interview: Ajay Menon
developing the energy sector technical exchange program collaboration and partnership
50-52 54-57 58-59 60-61
• Across the exhibition floor
Paparazzi Insight! Feature Process Analyzers Integrated Operations Asset Performance and Productivity Enhancement Functional Safety and SIS Featured Project Project Listing DMS Foundation
Dear DMS Automation Community, I wish to thank you all for the contributions you all made to make the 3rd ISA Automation EMEA Conference & Exhibition organised by DMS Global in Abu Dhabi during May 2015 a huge success. Whether you were a speaker, delegate, exhibitor or visitor, you are all an important element of the automation community we are trying to develop for the region and the industry. For those of you who could not make it enclosed in this issue is the post show report, and when you read what an amazing networking event it was, you will no doubt be rushing to join us for the next event. We are delighted to promote in the Company News Section the new Yokokawa corporate brand slogan CO-INNOVATING TOMORROW as they celebrate their 100 Year Anniversary. Huge congratulations to Yokogawa on this spectacular milestone. My thanks also to Endress+Hauser, Rockwell Automation, Telinstra & Kenexis for the great technical articles they provided for this issue of Automation Insight! as it is contributions like these that make this magazine the official voice of the Automation Sector in the Middle East. Kind regards, Mo Loch President and CEO DMS Global Dear DMS-Members, Since our last edition the 3rd ISA EMEA Conference & Exhibition has come and gone and we now look forward to the MEPEC and ADIPEC exhibitions with the low price of oil ever-present these days. There is obviously a lot of talk, analysis and conjecture surrounding whether the Gulf producers will cut-back on production and I’m not going to bore you with this but suffice it to say that the economies of the GCC have deep-pockets and need to diversify their economies. Much of this is coming from Petrochemicals and Power Generation which both need oil and gas feedstock and so exports of these resources may not be as large as before but investment in these industries will increase to power the ever-increasing domestic requirements and to win market-share of petro-chemically-based products given the geographic proximity advantage to the feedstock. As such projects continue albeit in slightly different industrial sectors and our industry remains strong. Of course we also need to consider Iran, who will, if the Iran government is to be believed, ramp-up production as early as October this year. If we see many Iranian visitors at ADIPEC I would suggest that we will be in for more projects in the coming years from across the Gulf. Hugh Wingrove Editor-in-Chief DMS Global SEPTEMBER 2015 | Automation INSIGHT! | 3
DMS ANALYTIC Saudi: Shaybah Arabian Light Crude Increment Program The super-giant oil field known as the “Shaybah Oil Field” is located in the northern edge Rub’ Al Khali/Empty Quarter desert. Shaybah was developed for the purposes of exploiting the Shaybah oilfield and was established by Saudi Aramco during the 90’s. The Shaybah oil field imposed major challenges during its discovery and development due to the temperatures that soared to 55 degree Celsius along with heavy dust storms and the shifting sands; however, underneath the harshness of its climate, the shaybah field has the best Arabian Extra Light Crude oil with a specific gravity of 42 degrees at depth of 4,900 meters, its sulphur content is also less than 0.7 percent. Currently, Saudi Aramco is implementing expansion plans at Shaybah field in the Empty Quarter to increase the production of Arabian light crude oil capacity by 250,000 barrels per day (bpd), doubling the initial capacity of Arabian light crude oil to 1 million bpd. This is also done to rebalance its crude quality and extend the lifespan of mature fields. Adding new capacity at Shaybah comes on top of several other field expansions announced by Aramco in 2013. In March that year the company said that it would develop two satellite fields at Khurais to produce another 300,000 b/d. Also, by late 2014, Aramco said that it would ramp up output from the offshore Manifa field to 900,000 b/d, up from some 500,000 b/d in March 2013. Moreover, the Saudi oil company is working to improve
4 | Automation INSIGHT! | SEPTEMBER 2015
the design of wells to increase the average reservoir contact to 10 km, which will enhance production from the deep, tight faces of the reservoir. The scope of works will be carried over by Samsung Engineering to expand the handling facilities which will increase the field’s capacity by 250,000 barrels per day (bpd). This includes expanding the existing facility at Shaybah GOSPs 1, 3, and 4 to increase their total handling capacity by 250,000 barrels of AXL crude. At GOSP 4, three gas oil separators and one wet crude handling train will be added along with the associated charge, disposal and shipping pumps, intermediate and booster gas compressor and all associated utilities. The project will also install additional oil transfer facilities with associated utilities at GOSPs 1 and 3. The expansion to the oil facilities is targeted to be completed by April 2016, which in turn will boost the company’s reputation even further along with its international role in responding reliably to future oil market demand. As part of expansion plans, Saudi Aramco will construct a new NGL plant to meet the growing demand for petrochemical feedstock through the extraction of high value NGL of the produced gas. Aramco uses natural gas as a vital alternative to reduce the Kingdom’s dependence on the liquid fuel to generate electricity and to lay the foundation for further development and economic diversification.
ANALYTIC
Saudi: SAMREF - Yanbu Oil Refinery Revamp - Clean Fuels Project In 1981, Saudi Aramco, the world’s largest oil producing and exporting company and ExxonMobil, a global energy company with a history of success dating back more than 132 years, formed a joint venture called Saudi Aramco Mobil Refinery Company (SAMREF) which lead to the construction of the SAMREF complex refinery for the development, construction, ownership and operation of crude oil refining facilities in Yanbu, Saudi Arabia. In March 2008, a new project to improve the refinery was announced by SAMREF. Project “Clean Fuels” aims to overhaul and upgrade Yanbu’s oil refinery’s current production of 400,000 barrels per day (bpd). The upgrading of the oil refinery will be carried out simultaneously in 2 phases. Phase 1 will be responsible for the constructions of a hydrogen unit, a fluid catalytic converter and revamping of a distillate hydrotreater and upgrading of the process units while Phase 2 covers the tie-ins for all process units, connections to the control system and the relocation of the refinery’s laboratory. The first package, which covers a crude and vacuum distillation unit to separate 400,000 barrels per day (bpd) of Arabian Crude into different streams, will then be used as feedstock for further downstream units. The second package is for three separate process plants. Two 70,000 (bpd) diesel hydrotreater units, a combined naptha hydrotreater and continuous catalyst regeneration facility. The third package on the table is the sulphur recovery
unit which comprises of three 150 tonne per day (tpd) trains including an incinerator to dispose of non-converted sulphur. A sour water stripper and flare system to allow liquid discharges into the atmosphere are also required. The fourth package involves covering utilities and asphalt handling facilities, including two 30MW steam turbine generators and two desalination units. The fifth package is a tank farm package that covers 31 new storage tanks, each with a capacity of 50,000 – 200,000 barrels, along with gasoline and fuel oil blenders. Changes of sulphur levels have been progressively introduced around the Gulf over the past few years as the region slowly moves into line with tough new US limits on sulphur dioxide emissions. Previously, sulphur dioxide emission levels were about 10,000 ppm. A decade later, they had been slashed to 2,000-5,000 ppm. The most recent US law change in 2006 requires gasoline to contain less than 10 ppm of sulphur and 1 per cent benzene by 2013. The overhaul is part of Saudi Arabia’s new product standards to meet the US environmental regulations. It states the Diesel must have less than 50parts per million (ppm) of sulphur by 2013 and 10 ppm by 2016. Samref yield is 35 per cent gasoline, 15 per cent fuel oil, 30 per cent heating and diesel, 17 per cent marine and other fuel oil and 3 per cent LPG. The plant mainly runs on Arab Light crude oil. SEPTEMBER 2015 | Automation INSIGHT! | 5
ANALYTIC
UAE: The Hail Offshore Oil Field In Focus
Abu Dhabi Oil Company Limited (ADCO) announced plans to develop the Hail offshore oilfield in the Emirate of Abu Dhabi in the United Arab Emirates. For the oilfield, located approximately 10 kilometers south of the Mubarraz island, ADCO is planning an expansion development which aims to increase the current production and secure the production for the next 30 years. Through being adjacent to the existing and operating oilfield of ADCO, the Hail offshore oilfield location provides space for carrying out of the development through the provided undeveloped reservoirs with capacity which is almost equivalent to the current rate of production of the existing oil fields available. Effectively, the phase one of the anticipated scheme consists of front-end engineering design (FEED) which has been carried out through the France’s Technip, receiving of the approvals, tendering of the engineering, procurement and construction (EPC) contract as well as execution, all managed by the UK’s consultancy firm, Mott MacDonald. The company, which has been allocated as the project management consultant to ensure high standard delivery of the mentioned activities, shall provide essential expert advise and solutions to ensure that the installment of production manifolds including wellheads, production, testing and utilities have been achieved effectively as per the desired ADCO standards. Effectively, the project teams assigned to the development of the Hail offshore oil field require to be completely aware and prepared for any complexities that may arise naturally 6 | Automation INSIGHT! | SEPTEMBER 2015
within the process of planning and execution of the project. Consequently, the nature of the offshore oil field is such that environmental and ecological aspects must not be ignored. Located specifically within the Marawah marine biosphere, the environmental challenges provided have a great impact on the scope of work and the way in which the project is planned, designed, engineered and delivered. Furthermore, the development requires a great deal of expert planning to overcome technical production challenges for the engineering and other works involved. More specifically, the zone in which the offshore oil field is located inhabits a deep gas field, which is laid within rock foundations below the Hail oil bands. In effect, earlier this year, Occidental Petroleum (Oxy) has been allocated a contract to provide assistance for the evaluation of the Hail offshore oil field. The exploration of the oil field embodies 3D seismic surveys, drilling of appraisal wells and conducing engineering studies to ensure complexities are thoroughly assessed and overcome. At the moment, with the engineering, procurement and construction (EPC) tendering already floated, the assigned project team is evaluating bids and industry talks reveal that the final stage of the process is currently in place. Talks remain that currently there are two companies bidding and possibly a third company maybe included. A definite interest amongst the industry is currently present and the companies are hoping to see the award of the EPC contract within the upcoming months.
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ANALYTIC
UAE: Satah Al Razboot Continues The Abu Dhabi Marine Operating Company (ADMAOPCO) has been carrying out the development of the previously tapped Satah Al Razboot (SARB) oil field in Abu Dhabi, UAE. Located approximately 200 kilometers northwest of Abu Dhabi oilfield is expected to add an additional 100,000 barrels per day of oil to the country’s outcome by the year 2016. With completion of the front-end engineering design (FEED) through Fluor back in 2009, the project, which incorporates several different phases, will eventually boost production capacity of Abu Dhabi’s offshore fields from its current 1.1 million barrels per day to 1.75 million barrels per day by year 2020. The islands, which make up the SARB oil field, are being developed with purpose of serving foundations for drilling which shall in turn lessen the need to construct and utilize the offshore oilrigs. The project, which involves drilling oil wells, constructing platforms and bridges, will eventually allow oil to be drilled from the wells and transferred via the subsea pipeline to the newly developed facility, which shall be built at the Zirku island. The facility shall then be used for processing, storing and exporting of the oil. The phase 4 of the SARB oil field development, whose project management consultant (PMC) is Jacobs Engineering, incorporates construction of main processing facilities at Zirku island and the artificial island. The development of the onshore facilities consists of SARB one and two well gathering facilities and support requirements, crude stabilization and crude storage and export from Zirku and injection of water and gas. Utilities, buildings and infrastructure are also being developed to support the
8 | Automation INSIGHT! | SEPTEMBER 2015
overall production. Effectively, aside from processing oil, the Zirku island facilities are planned to have the purpose of processing gas; disposal; and treat produced water, which will be treated at Zirku facilities and disposed through ZADCO disposal wells. The package involves installation of facilities for SARB reservoir pressure management for gas and water injection; and the required gas make-up for gas injection will be sourced from drilled wells at the offshore artificial islands of SARB. These facilities include, pigging, oil processing, storage and loading, water injection and waste water treatment, chemical injection, flares, power generation and utility systems. As far as the artificial island facilities are taken into consideration, pre-installment of 2 artificial islands will be carried out with 86 drilled wells with piping, manifolds, chemical injection and control facilities for oil and production, multi-phase flow meter well testing, gas and water injection. The scope of work for this particular section therefore includes installation of pipelines, interconnected piping, manifolds, well clusters and flow lines, wells testing and intelligent wells for data acquisition. Gas injection, chemical injection facilities, hydraulic unit and emergency power generation. To ensure immaculate delivery of the planned development, which is continuously progressing, the appointed engineering, procurement and construction (EPC) contractor Hyundai Engineering and Construction continues with construction activities with purpose of reaching completion and delivering the project as per ADMA OPCO’s desired standards and expectations.
ANALYTIC
Qatar: Al Shaheen Tender - A QP Strategy to Low Prices?
In recent years, Qatar’s crude oil production had been declining with costly field development plans becoming untenable as oil prices plunged. With all these factors brewing, the troublesome ingredient of production sharing agreements expiring are thrown into the pot – most notably on the largest field, Al Shaheen. This series of events gave Qatar Petroleum’s (QP) new managing director an opportunity to push partners hard on cutting costs for production. And none knew this better than Maersk Oil. Off the north east coast of Qatar in the Persian Gulf, 80 kilometers (50 mi) north of Doha in an area known as Block 5, is a production oil and gas reservoir discovered by Maersk Oil in 1992. Al Shaheen partly overlaps with the North Field but at a shallower depth, extending over a wide area of around 2,500 sq. km but is only a few meters thick in places. The reservoir has long been considered commercially unviable until Maersk applied horizontal drilling techniques that it had developed by operating fields in the North Sea, eventually leading to the first oil production in 1994. In 2010, Al Shaheen eventually reached a production level of around 300,000 barrels/day (b/d). Today that production level comprises about 45% of Qatar’s total crude production of 660,000 b/d for the first quarter of 2015. There had been plans to boost this level further to 525,000 b/d but these were scrapped in 2011 after surveys resulted in a 60% downward revision in its reserves. Because of this, maintaining the current production plateau has been the focus of Maersk’s current investments.
Given this pivotal role played by Maersk Oil in a reservoir central to Qatar’s oil sector, it had been safe to assume that the company would carry on as operator without the challenge presented by a competitive tender. That assumption proved to be flawed when Qatar Petroleum opened an invitation for international oil companies to bid for Al Shaheen. The announcement came as a blow Maersk as it sees its 25-year exploration and production sharing agreement (EPSA) with QP expire in mid-2017. Mr. Kaabi was quoted as saying that the basis for tender criteria is “the best technological solutions for the field’s development combined with the best financial return to the state.” Maersk may very well bag the new bid for Al Shaheen but the tender will likely exert greater pressure on margins. It could also possibly result to delays in current investment programs including the drilling of 51 wells at a cost of $2.5bn – particularly if the tendering process is slow. In response, Jakob Thomasen, Maersk’s CEO was quoted as saying “We have developed an unrivalled technical experience and understanding of this complex offshore field and have a robust plan to deliver future value from Al Shaheen. We have known that we would be challenged on terms and conditions in connection with the 2017 extension and have been awaiting more information on how Qatar Petroleum wished to go about such a process. We look forward to this opportunity to continue our partnership with Qatar Petroleum, based on our long term commitment and detailed technical knowledge.” SEPTEMBER 2015 | Automation INSIGHT! | 9
ANALYTIC
Bahrain: Bapco progresses well with its Modernization Programme Bahrain plans to add 100,000 barrels per day (bpd) of new refinery capacity to its Bapco plant beyond 2016 under the Bapco Modernization Programme (BMP). Currently producing up to 260,000 barrels per day, Bapco’s refinery expansion plan is reliant on boosting the capacity of a pipeline that brings 220,000 bpd of crude to the plant from Saudi Arabia. Up to this point, the programme is Bapco’s most ambitious project and has been estimated to cost over US$5 billion. Project management, engineering and construction firm Technip Italy has been appointed to carry out the front-end engineering and design (FEED) for the Bapco Modernisation Programme (BMP). The FEED project is expected to take 16 months to complete. Technip Italy chief executive Mr. Marco Villa, has expressed that they are confident in completing the front-end development work on schedule and within budget. He has also stated that the company will employ its offices in Abu Dhabi and its high-value engineering centre in Greece for the project. Prior to being chosen as the bid winner, Technip has had some tough competition vying for the FEED contract for the Bahrain Modernization Programme project. Some of Technip’s bid competitors have been Netherlands’ CB&I, Bechtel Ltd, WorleyParsons, and a joint venture between JGC Corporation and KBR. After close evaluation and meticulous reviewing of all bids, Technip has been successful in bagging the contract with the proposed budget of about US$ 63.5 million for the front-end engineering and design. The scope of Technip’s work involves converting bottom
10 | Automation INSIGHT! | SEPTEMBER 2015
of the barrel components into higher-value products. One of the main goals of Bapco Modernization Programme (BMP) is to improve gross refining margins and cost-efficiencies. The refinery configuration once the project has been completed would allow for higher output, improved product quality and ensure Bapco’s continued competitiveness under a wide range of prices and market scenarios. The project would also improve energy efficiency and address all local environmental compliance requirements anticipated in the near future. Key components of the project will include a crude unit and associated facilities, hydrocracker and associated facilities, residue conversion units and a waste treatment facility. The residue conversion unit will put forward an opportunity to cheaper feedstock of heavy crude oil and thus, a larger diversity of sources of supply. The hydrocracker and associated facilities will include a new hydrocracking unit with 60,000 bpd capacity, expansion of the mild hydrocracking unit from 54,000 bpd to 70,000 bpd capacity and a new fluid catalytic cracker. A dehydrosulphurisation unit is also planned to produce diesel according to international standards with sulphur content of less than 10 parts per million. Once the design packages have been concluded by early 2016, the engineering, procurement and construction stage would begin with commissioning of the new units anticipated by 2020. As for the latest update on the project, CH2M Hill has been awarded the front-end engineering and design for the Number 3 API separator unit.
ANALYTIC
Oman: Long-delayed Musandam Independent Power Project Finally Breaks Ground Musandam Power Company has finally broke ground on the Musandam Independent Power (IPP) project. Sarooj Construction Company, who has been awarded the $31 million contract by Wärtsilä Finland, is carrying out the Early Civil Works. Oman Oil Company’s (OOC) majority owned subsidiary Musandam Power Company signed in December last year the engineering, procurement and construction (EPC) contract and Long Term Service Agreement (LTSA) with Wärtsilä Muscat LLC for building the new dual fuel fired Power Plant. Under the agreement, Wärtsilä will design, procure and manage the construction of the 120MW gasfired power plant, as well as provide on-going maintenance and performance monitoring during the concession period of 15 years from the commissioning date. The plant is being constructed at a seafront land in Tibat-Wilayat Bukha at Musandam Governorate. As the Musandam peninsula is separated from the rest of the country, its electricity grid is also independent from Oman national grid. Musandam Power Company has been awarded the EPC contract following a completive pre-qualification and tendering process to deliver flexible and sustainable energy to the Musandam Governorate. The pre-qualified bidders for the EPC contract were: • Wartsila Finland OY through Wartsila Gulf • Consortium of Kharafi National and TSK • Iberdrola Ingeneria Y Construction • Bharat Heave Electrical ltd. • STX Heavy Industries Co. • Consortium of Ghantoot - Utico FZC and Burmester & Wain • Consortium of METKA and Power Projects • Siemens • Doosan Heavy Industries and Construction Co. • Consortium of Global Chemicals and
Parsons Brinkerhoff • Duro Felguera • Consortium of Towell Engineering Services Co., and TR • J&P • SEPOO III Electric Power Construction Corp. • Abiensa Ingeneria y Construccion industrial • Consortium of Galfar Eng. and Initec Engergia The environmentally-friendly Musandam Power Plant will use clean natural gas as main fuel and will also accept diesel fuel as a back-up fuel to maintain the stability of the local electricity supply and support sustainable development in the Governorate while significantly contributing to the Sultanate’s energy-production capabilities and long-term economic diversification plans. Construction of the new power plant is scheduled to be ready for full operations by the last quarter of 2016. The joint venture between OOC, holding a 70% stake, and LG International form South Korea, retaining 30% stake, was established in 2014 as Oman’s first Independent power plant in Musandam and uses fuel gas processed by OOC’s wholly owned subsidiary, Oman Oil Company Exploration and Production (OOCEP) from the adjacent Musandam Gas Processing Plant. The gas plant has recently been commissioned by a joint venture of Hyundai Engineering & Construction and Larsen & Toubro. A multiphase offshore pipeline import fluids from the West Bukha field located close by in Omani waters to Musandam Gas Plant for processing. Ahead to the break ground activities, the Musandam Power Company has awarded Pöyry Project Management Consultancy (PMC) and engineer services contract for the project. Pöyry’s work includes the design review of the EPC contractor documentation as well as technical and site supervision services. SEPTEMBER 2015 | Automation INSIGHT! | 11
ANALYTIC
Kuwait: KNPC to Build the Largest Refinery in the Middle East
Al Zour Refinery, also known as ZOR, is an upcoming project being developed by the Kuwait National Petroleum Company (KNPC). KNPC had first released plans to build what would have been the country’s fourth oil refinery in May 2008 but the project was cancelled in March 2008 due to political opposition. Two years later, however, the government re-approved construction and KNPC anticipates completion around 2018. The Supreme Petroleum Council (SPC) had approved the project in February 2012 and the approval from the KuwaitEnvironment Public Authority (K-EPA) has also been granted site preparation works started this year. The new refinery will be designed to process 615,000 barrels a day of Kuwait export crude (KEC) or 535,000 barrels a day of mixed heavy crudes. Overall investment for the project is estimated to reach KWD6.7bn ($23bn). The Refinery will primarily supply 225,000 barrels a day of low sulphur fuel oil (LSFO) to local power plants. It will also produce jet fuel, kerosene and naphtha feedstock for petrochemical plants. Among the main facilities at the refinery are three atmospheric residue desulphurisation (ARDS) units featuring two trains each, three crude distillation units (CDU), three diesel hydrotreating units (DHTU), two naphtha hydrotreating units (NHTU) and two kero hydrotreating units (KHTU). Other facilities include two saturated gas processing plants, a heavy oil cooling (HOC) unit, a hydrogen recovery (HR) unit, a hydrogen compression (HC) unit and four trains of hydrogen production units (HPU). The project also includes the installation of a sour water stripper (SWS) unit comprised of three trains, 12 | Automation INSIGHT! | SEPTEMBER 2015
three amine regeneration (AR) plants, three sulphur recovery units (SRU) and tail gas treating units (TGTU). Other installations include a hydrocarbon flare system, four sulphur pelletising systems integrating two circular storage tanks and sulphur conveying systems, two acid gas flares, and four sulphur storage tanks. Associated project activities will include the installation of a sulphur pelletising system, a steam generating unit, air systems, water treatment systems, a cooling water unit and high voltage (HV) substations to receive power from the Al-Zour South Power Station (AZPS). Project activities also involve feedstock and product supply pipelines, and construction of various channels, a basin for a future jetty, a barge dock, and roads. AMEC has been awarded the contract for Project Management Consultancy (PMC) while Honeywell will provide its proprietary Experion PKS integrated control and safety system (ICSS) to serve as the main control system. Van Oord has also been awarded a contract to carry out dredging works at the project site. The project is part of the OPEC oil producer’s 30 billion dinar development plan, announced in 2010. Such mega projects are a test for Kuwait, which has struggled to upgrade its infrastructure and attract foreign investors, partly due to political instability and bureaucracy. The ZOR project and the Clean Fuels project (CPF) are the two biggest projects being implemented as part of KNPC’s 2030 strategy. The new refinery will account for 43% of the country’s refining capacity, and will be the largest in the Middle East. ZOR Project will be one of the largest refineries in the world when it comes online in 2018.
COMPANY NEWS
Yokogawa Establishes Corporate Brand Slogan to Encourage Creation of Value and Pursuit of Growth with Customers
Yokogawa Electric Corporation announces that it has created a corporate brand slogan to encourage the joint pursuit of activities with its customers that will create value and foster growth. The global rollout of this new slogan, Co-innovating tomorrow, is set for September 1, the 100th anniversary of Yokogawa’s founding.
About the corporate brand slogan
The decision to create this new slogan has its origins in dramatic shifts in our business environment that are the result of globalization, the transition to a multipolar world order, and the industry changes that are accompanying the increasing integration of things and information. In response, Yokogawa has drawn up a long-term business framework and formulated a vision statement that reads, Through “Process Co-Innovation*”, Yokogawa creates new value with our clients for a brighter future. We are now accelerating our efforts to
About Yokogawa
bring about a transformation that will allow us to sustain growth for another 100 years. To share the essence of this vision statement with our stakeholders and encourage all employees to join forces in the pursuit of this initiative, Yokogawa has established the corporate brand slogan of Co-innovating tomorrow. The term Co-innovating conveys our determination to engage in the co-creation of value through the development of solutions in long-term partnerships with our clients. tomorrow expresses our resolve to move steadily into the future one step at a time. Under this new slogan, Yokogawa will seek to establish even stronger bonds of trust with its customers by working with them to create value and stimulate growth. * Process Co-Innovation: A concept for an automation business that will utilize all of Yokogawa’s measurement, control, and information technologies. According to this concept, Yokogawa will seek not only to optimize production processes but also the flow of material and information within and between companies, including their value and supply chains. This concept will encompass the entire range of Yokogawa solutions and will entail a commitment to working with clients to create new value on their behalf.
Yokogawa’s global network of 88 companies spans 56 countries. Founded in 1915, the US$3.5 billion company engages in cutting-edge research and innovation. Yokogawa is active in the industrial automation and control (IA), test and measurement, and aviation and other businesses segments. The IA segment plays a vital role in a wide range of industries including oil, chemicals, natural gas, power, iron and steel, pulp and paper, pharmaceuticals, and food. For more information about Yokogawa, please visit www.yokogawa.com 14 | Automation INSIGHT! | SEPTEMBER 2015
Hosted under the patronage of His Excellency Dr. Abdul Hussain bin Ali Mirza Minister of Energy and Chairman, National Oil Gas Authority (NOGA)
Hosted By:
Supported By:
Be a part of the Heavy Oil Industry in the Middle East and join the Middle East Heavy Oil Congress as an Exhibitor, Sponsor, Delegate For more information to participate please contact us: mehoc@dmgeventsme.com; Tel.: +971 2 6970 500 FOR EXHIBITION & SPONSORSHIP OPTIONS PLEASE CONTACT: Jeremy George, Sales Manager, Tel.: +971 4 4380 355, Email: JeremyGeorge@dmgeventsme.com INTERESTED TO SHARE YOUR KNOWLEDGE AND EXPERTISE? CONTACT: Varkha Israni, Tel.: +971 2 6970 504 Email: VarkhaIsrani@dmgeventsme.com TO LEARN MORE ABOUT SPEAKING OPPORTUNITIES Presented By:
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Official Publication:
Post Show REPORT
Automation taking important role in developing the Energy Sector: ISA 2015 Post Show report 16 | Automation INSIGHT! | SEPTEMBER 2015
POST SHOW REPORT With the recent drop in oil prices around the world, the demand for efficient, safer and cost effective operations by End Users of the Energy sector has increased, thus forcing the automation industry to play a bigger and important role in the growth of the Energy Sector. And with bigger importance comes bigger responsibility, as the growing needs for communication between the Automation Industry and the End Users take on a critical turn. However it isn’t just better communication that is needed, but a platform where professionals can network, share best-case practices and knowledge. A platform like the 3rd ISA Automation Conference and Exhibition 2015, which was held on the 26th of May 2015 at St. Regis Saadiyat Island, Abu Dhabi, U.A.E. Officially supported by ADNOC, ISA Automation Conference & Exhibition 2015 offered a unique opportunity for automation professionals, equipment manufacturers and service providers to share and exchange experiences and explore the latest products 2% and most recent innovations and technologies. 2% This two day conference attracted over 730 participants and over 35 exhibitors, while 1% tackling the following conference topics:
Job Titles/ Designation President/Managing Director
11% 9% 14% 30% 29% 7%
Other Department Directors
Managers/Supervisors/ Heads Consultants/specialists Engineers Students/Media/Other Executives
No. of visitors per region
16%
• Industrial Control System Cyber Security • Asset Performance & Productivity Enhancement • Advanced Process Control & Optimisation • Industrial Control System Cyber Security • Multi-Phase & Wet Gas Flow Meters • Custody Transfer Measurement • Functional Safety & SIS • Digital Oilfield / Wireless & Industrial Communications • Integrated Operations • Obsolescence & Lifecycle Management of Control & Safety Systems • Alarm Management • Process Analyzers – Emerging Trends and key Factors for Successful Implementation
Middle East and Africa United States
79%
Europe Asia Other
2%
Type of Companies
30%
6%
62%
National oil Companies Vendors EPC’s Others
SEPTEMBER 2015 | Automation INSIGHT! | 17
POST SHOW REPORT
The importance of Automation and a Technical Exchange Platform The first day of the ISA Automation Conference and Exhibition 2015 opened doors at 8.00 am on the 26th of May for registration. Preceding the registration was the official opening ceremony of the conference which contained keynote speeches on the importance the role automation plays in the industry and why a technical platform such as the ISA Automation Conference and Exhibition 2015 is just as important. A few memorable moments for the keynote speeches were:
Keynote speaker, Mo Loch, CEO, DMS Global, said: “I firmly believe that there is no better way for any automation expert and enterprise decision maker to keep abreast of rapidly developing technology in the automation industry than attending the highly specialized conferences and exhibitions such as this. It is indeed the most time- and cost- effective way to get familiar with new products and solutions by hearing the technical presentations from leading industry experts and by seeing the physical products at the exhibition booths. Furthermore, this is a great opportunity for end users to exchange knowledge on their experiences with these products and services.” 18 | Automation INSIGHT! | SEPTEMBER 2015
Keynote speaker, Abdul Nasser Al Mughairbi, Senior Vice President, Habshan Complex Abu Dhabi Gas Industries Ltd. (GASCO), said: “I think corporate events within the region, that brings together different people from all around world, helps us all to align each other to new strategies as well as new opportunities. We gain a new understanding of what is automation and what does it mean for our industry and to the core business of production and automization. ADNOC has been taking a more strong liberal approach in automation; it was previously more conservative. In our sister companies in the upstream business, smart field automation and decision making processes are automated to help manage the field. We use advanced process control in all our plants as well as real time optimization. We utilize data for process safety KPIs, and implement certain standards in process safety within the utilization of automation. I think it is very important for all of us; I keep saying the word important because really, automation now is becoming the heart of the industry. Everybody uses it. We use automation in our mobile phones. We use automation everywhere. Even people who reject automation have to use it on a daily bases.”
POST SHOW REPORT
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Keynote speaker, Yahya Darwish, Country Manager, Rockwell Automation, KSA and Bahrain, Said: “By 2020 population will exceed 7.6 Trillion with more that 70 million crossing the middle class, which will add around 8 trillion dollar to consumer spending. But what does this mean? This means it will lead to an increase demand of around 60% for water, 80% for steel, 100% for vehicles and 150% for energy. So with a huge base, how can we benefit, protect and progress our business?” “I have met lately with many subject matter experts within the industry sector, none of them have not faced these challenges. As Eng Abdul Nasser has already mentioned, these challenges are standard challenges we face with our end users on a daily bases. Increased productivity, which will result in more complex operations, enterprise risk management, that we need zero tolerance to enhance safety and cyber security. Faster time to market. Leading to increased market share. Total cost of ownership including equality and compliance as well as improved asset utilization.”
SEPTEMBER 2015 | Automation INSIGHT! | 19
POST SHOW REPORT
MOXA and Telinstra FZCO announce regional Collaboration and Partnership
Telinstra FZCO recently signed up certified System Integration Program with MOXA for the region. With this agreement, Telinstra plans to bring state of the art Industrial Networking solutions to our clients in the region. MOXA’s networking equipment will widely be used by Telinstra for our PLC, RTU, ESD and SCADA solutions that we offer to clients in the region. The above agreement was signed during 2-days ISA Automation Conference and Exhibition on 27th May 2015 held at St. Regis Hotel, Saadiyat Island in Abu Dhabi. This conference and tradeshow in the Gulf Region was dedicated for process automation with latest automation technologies and products from the vendors across the world. It was the unique opportunity and platform for automation professionals, equipment manufacturers and service providers to share and exchange their experiences and explore the latest products and most recent innovations and technologies. “MOXA has been a leading networking solutions provider with over 25 years of experience in industrial automation. We are glad to have Telinstra on board as a partner to provide industrial networking solutions to the customers. We believe Telinstra has the required potential and will prove to be one of the best partners for us in the region.”– Pradeep Kumar, BDM, D-Link Middle East & Africa (MOXA Division) 20 | Automation INSIGHT! | SEPTEMBER 2015
POST SHOW REPORT
Rockwell Automation highlights Plant PAx
The company displayed world-class distributed control system (DCS) combined with plant-wide control technologies and unmatched scalability of Rockwell Automation Integrated Architecture®. The 3rd ISA Automation Conference & Exhibition 2015, a full-scale conference and tradeshow in the Gulf region dedicated for process automation, successfully concluded recently. The two-day event was held at St. Regis Hotel in Abu Dhabi on 26th and 27th May this year with Rockwell Automation being the Diamond Sponsor. Participants from key industries engaged with automation and control professionals, manufacturers, business leaders and discuss the latest technologies, solutions and products available in the market. In addition to this, regional and international experts and decision makers have imparted their vision and solutions to the challenges of measurement and control in complex industrial environments. At the exhibition, Rockwell Automation
displayed its technical and automation capabilities within their 45 square meter show floor through their single integrated plantwide solution – PlantPAx PlantPAx represents a new generation of integrated, scalable solutions for large control, safety and power systems solutions that exceed control and safety functionality typically found today. A PlantPAx solution integrates process, power, safety and critical control in a single unified platform and offers unprecedented levels of control, and flexibility via: • System tools that enable configuration in a common environment • A single, integrated database and common tag structure to simplify engineering; and • A library of reusable control objects to shorten project development time. At the conference, subject matter experts from Rockwell Automation Europe and Middle East presented four technical papers on Advanced Process Control and Optimisation, Industrial Control System Cyber Security, Digital Oil Fields, Wireless & Industrial Communications and Integrated Operation. Rockwell Automation is keen to support ISA in all future conferences and exhibitions in the region. SEPTEMBER 2015 | Automation INSIGHT! | 21
POST SHOW REPORT
Across the Exhibition Floor
During the two days of the conference and exhibition we had a chance to explore the exhibition floor and speak with some of the companies exhibiting. We first me up with Raymond Joyce, Country Manager of Yokogawa, Also one of the conference’s Gold Sponsor. Our first question to him was, what does Yokogawa do? Yokogawa is into instrumentation & control, mainly in oil & gas, here in Abu Dhabi we are very fortunate that we work very closely with the ADNOC group of companies, ADCO, GASCO, ADMAOPCO, Takreer and many of the other companies. Because we have manage to locate ourselves over here, build engineer systems, the group of ADNOC companies have given us orders, which we complimented by training their local engineers, as the government has a focus on training Emirati engineers and we would like to contribute in this manner and also train them. This will be an ongoing process which would probably take a number of years. What do you think about the Conference? ISA has always been an impressive organization in terms of education and so we are very proud to be associated with ISA. ISA for us focuses on what we are deliver, which is controls and instrumentation, there are many shows which we can participate in, but this is very tightly focused on the types of products we deliver and the solutions we deliver. This is why we like working with ISA. And our last question, What are the future plans for Yokogawa? Very recently, about 18 months ago we took on the responsibility of Africa, so now it is Yokogawa Middle east and North Africa. There are number of changes happening within the organizations, such as growth, it is exciting times and we are excited about the prospect. 22 | Automation INSIGHT! | SEPTEMBER 2015
We next met up with Raphael Torrano, Regional Sales Manager at WEG. Our first question to him was, what does WEG do? WEG is an international company with the head quarters in Brazil, WEG makes many type of products for the industry specially for oil & gas. Some of the products we make are motors, VFDs, soft-starters (including their panels), generators, transformers and many other products for industrial application. What do you think about ISA and the Conference? WEG is a company started in the 1961, and sometime along the way we decided to invest into automation, and that is the main reason why for us to be here, To showcase our portfolio and be around other manufactures. The event is a good opportunity to share case studies and seeing what is new in terms of Automation. We are proud to be here and proud to be promoting our brand. It has definitely been a good investment. And our last question, What are the future plans for WEG? WEG is well known as a supplier of products. In the future we would like to see WEG become more of a solution provider all over the world. Our goal is to be the number one player of intersole solutions.
POST SHOW REPORT
Our third stop on the floor was at KPS, where we had the pleasure of meeting Mathias Rubien. Our first question to him was, what does KPS do? KPS is an O & M manufacturer of automatic sampling systems for the oil and gas industry. We handle sampling systems for onshore and offshore locations for all kinds of applications, like inline sampling, first loop sampling, IE-jet sampling for all major customers and EPCs. What do you think about the Conference? The reason to participate in the region of UAE, Oman or Saudi Arabia, is the huge potential of the oil and gas industry and after developing our products in Europe, we found now is the time to show the world there is another player in the market who is capable of solving problems and bring solutions that help as well as save money. Conferences are all about quantity and quality of people, we tend to have problems and questions and are looking for the right answers to create the right solutions, Something like ISA is the right exhibition to participate in. And our last question, What are the future plans for KPS? The future of KPS is to grow and get attention as well as build up trust within the region, Mainly because we think we can provide good technology and we can also provide the latest technology while helping save cost.
We had a chance to sit down Diamond Sponsor’s Gert Thoonen, Process Technology Consultant, Rockwell Automation. Our first question to him was, what does Rockwell Automation do? Rockwell Automation is a sole supplier of automation systems like process control systems. We only do process control; it is our business. Integrated solutions. Here we are showing our modern EDS system fully integrated with an automation control and also digital oil fields. What do you think about the Conference? We are joining the ISA event because we think it is a great opportunity to showcase our newest technologies, but also to contribute to the community about safety and security and new technology trends. The ISA event is very organised and is in a lovely place and we see a lot of customers coming up so we get a lot of interaction with customers discussing new projects and revamps for old projects that they are planning because technology is changing and also the process industry needs to change. If we look at all the oil fields currently running, most of them are running for 20 years so you need to do a migration because these technologies used in the old times are obsolete and I think it is a big opportunity to do these migrations to prevent accidents that could happen with these old systems. The people who understand these technologies aren’t available anymore that understand these technologies. Young engineers are not aware of the older applications used in past times. And our last question, What are the future plans for Rockwell Automation? The future for Rockwell is the connected enterprise where we connect our automation part with the IT environment because everyone is hungry for information and data so we need to be able to report in a safe way, forward this information to the right person and have the format of the data become more meaningful to the end user. SEPTEMBER 2015 | Automation INSIGHT! | 23
POST SHOW REPORT
Next we visited the Kenexis stand, where we had the pleasure of meeting Edward M. Marszal, President & CEO of Kenexis Our first question to him was, what does KPS do? Kenexis is a technical safety consultancy. We are engineers that are focused on the intersection between process safety and instrumentation & control. What we do is use our skills in process engineering and risk analysis to analyze process plans to identify areas where hazards can occur and then we use our instrumentation design skills to engineer safeguards to prevent those hazards from being realized. We are also a company that is pioneering the concept of fire and gas mapping and have developed cutting edge 3 dimensional software to analyse where fire detectors should be placed. In addition to our core technical safety, instrumentation and control systems cannot we do a lot of cyber security analysis. What do you think about the Conference? Kenexis has been a very long-standing participant in ISA. We’ve partnered with ISA for years. I am personally an author of an ISA book on layer of protection analysis so I’ve been an ISA author for about 15 years now. We actively participate in ISA because we find that it’s a great way to pass information from vendors and other experts out into the user community. This particular conference has been great. The participants who have come to the show are really good. It’s a very high quality show with a lot of good vendor exhibits, a lot of great technical discussions. We’ve had a great time here so far and we are just getting started. We were very happy with the show in Dammam a year and a half ago and we will certainly be in the next one. And our last question, What are the future plans for Kenexis? Kenexis is growing worldwide. We have grown in our product lines; we started just doing the safety-instrumented systems and with the pioneering of fire and gas mapping, we’ve kind of added into our service list and we are starting to grow more in different regions. We came to the Middle East in 2010 when we first started doing work for some of the ADNOC companies and we’ve expanded our base here and we are planning on bringing more staff into the UAE and also the other GCC countries because there are a lot of opportunities here. 24 | Automation INSIGHT! | SEPTEMBER 2015
Lastly we visted Endress+Hauser, one of the conferences silver sponsor, where we had the pleasure of meeting David Hewitt, Sales Director at Endress+Hauser Group Our first question to him was, what does Endress+Hauser do? We recently opened our operation in 2014 January here but as a company we’re a global company with a turnover of 2 billion Euros and we are a company that has manufacturing facilities in Europe and across the globe. We focus on process instrumentation; we call ourselves the people for process automation. Our products would be pressure level temperature analysis. The products that we offer to our customers are wide spectrum of designs for different industry segments. Today here, we are mostly oil and gasfocused but we do manufacture other products for food industry, water industry etc. What do you think about the Conference? It’s been a very good day today, we’ve had people from Gas Co. for instance, and ADGAS. We’ve had some consultants like ILF. Overall the day has been a very productive one. I think it’s a good venue for networking where you can meet like-minded people, transfer of knowledge. I think ISA is important for the region and we are very focused in supporting this and Endress and Hauser looks forward to supporting you. And our last question, What are the future plans for Endress+Hauser ? Endress and Hauser started with four people in 2006. We are now over 160 people in the region. We have offices in Qatar, Saudi and UAE office is the latest one we have opened. We have offices in Abu Dhabi and Dubai. What’s the future for Endress and Hauser in the Middle East? At the moment all I can say for the UAE office is that in 2020, we hope to double our turnover in this region with oil and gas being a major part in that.
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Building a wireless future to last
Harnessing The Power www.yokogawa.com/an
PAPARAZZI | AUTOMATION
ISA Automation Conference and Exhibition
Abu Dhabi, UAE
26-27 May 2015
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AUTOMATION | PAPARAZZI
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PAPARAZZI | AUTOMATION
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AUTOMATION | PAPARAZZI
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PAPARAZZI | AUTOMATION
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AUTOMATION | PAPARAZZI
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INSIGHT! FEATURE
Interview with
Ajay Menon
32 | Automation INSIGHT! | SEPTEMBER 2015
INSIGHT! FEATURE What does Telinstra do? Telinstra is a Specialist Consultancy and System Integration company. We provide turnkey solutions in Automation, Control, Instrumentation and Electrical Systems. To put it simple, we specialize in taking up turnkey projects from the clients which usually encompasses the complete Life Cycle of a Project, right from the Conceptualization to the Design, to Software Development to Manufacturing, factory testing and then finally Delivery and Installation at the client’s premises as well as Commissioning of the whole system. We also handle post contract support such as Training and Maintenance support for the clients. To sum it up the entire Project Life Cycle is handled by us. Why did Telinstra participate in ISA? An ISA event is a very good platform for any automation company to showcase their specializations and expertise. The International Society for Automation is a non-profit organization which has gained its reputation over the last 70 years of its operation. It is an organization which has given several standards to the industry and has been responsible for training thousands of professionals. In an event organized by ISA we should literally expect all the whos’s who in automation business. I think it is an appropriate platform for any automation and instrumentation Company to be present and to be showcasing their talent and their expertise to
clients. At Telinstra we couldn’t miss this opportunity as this was the first such event in the region. How do you feel about the ISA event thus far? It has been very well organized and an excellent event. The two days, thus far, have been excellent. This is the first ISA Exhibition and Conference in the UAE, And the Third in the region. The first two had taken place in Qatar and Saudi Arabia, So this is the first exposure to ISA within the UAE Region. I think the event has been very good, we have a good response from Venders, Sponsors, as well as the End Users. As the President of the ISA UAE section, I am totally satisfied by the way this exhibition and conference was organized, planned and executed. I think the organizers, DMS has done a commendable job by efficiently handling the entire show on behalf of ISA. What is the future of Telinstra? Telinstra are an aggressive organization who would like focus on providing the latest technology and the best solution to our clients with a focus for on time delivery and with the highest quality of the deliverables. Our intention is to provide our expertise not only to the UAE market but to the GCC region and probably even beyond that.
Our aim and vision is to be known as the best automation and controls company in the region through unparalleled service to our clients.
Telinstra firms up partnership with Moxa at the ISA exhibit SEPTEMBER 2015 | Automation INSIGHT! | 33
INSIGHT! FEATURE
Telinstra team with the CEO of Horizon Energy, Mr. Mahmud Haji
Telinstra are a leading provider of turnkey solutions in Advanced Control & Automation (PLC, SCADA, DCS & RTU) systems, Process Instrumentation, Safety Systems (ESD, F&G, HIPPS), HVAC Control Systems, Pipeline Automation Systems, Switchgear & Motor Control Centers, Power System Study, Centralized Control Rooms, Real-time Business Intelligence, Asset Management, IT Services, Enterprise Mobility Solutions, Enterprise Risk Management, Change & Communications. 34 | Automation INSIGHT! | SEPTEMBER 2015
What is Telinstra’s business? Telinstra provides bespoke solutions and advisory services to some of the Middle East region’s most important clients in the Oil & Gas, Utilities, Transport, Water and Waste Water, District Cooling, Infrastructure and Manufacturing sectors. What are your plans and areas of focus for 2016? From our centre of operations in Dubai, Telinstra aims to become the regional leader in delivering Integrated Automation, Electrical & Business Solutions to our Clients by way of providing Consulting, Technology and Services. Telinstra’s plan for 2016 is primarily to consolidate its business in the UAE and to expand into the other GCC countries with Qatar, Oman and Kuwait being the key focus. We are also looking at expanding our operations in India and in West Africa. Telinstra’s key focus would be to bring the latest technology to its clients but at the same time identify improvement opportunities, reduce waste and energy consumption and encourage and drive sustainability. It would also implement change management to encourage new ways of working as it is key to free up internal resources and focus on one’s core business. Telinstra is also planning to bring specialized sustainability management along with an efficient and timely reporting to meet the growing sustainability demands by regulatory authorities and stakeholders.
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PROCESS PROCESSANALYZERS ANALYZERS
Moisture Measurement Problem in Refinery Catalytic Reformer Operations – solved! Author: W. Gary Engelhart – Product Line Marketing Manager, SpectraSensors, Inc.
The Catalytic Reformer Unit in modern refineries converts naphtha into high-octane aromatic compounds termed reformates used in gasoline blending and formulation, and hydrogen. Semi-regenerative reformers (SRR) are the type in most widespread service in refineries. An SRR typically has three fixed bed catalytic reactors (Figure 1) employing platinum or rhenium catalysts on an alumina support. In operation, naphtha and recycled hydrogen gas are mixed, preheated and passed through the reactors. Water along with a chloride compound is injected to chlorinate the alumina and maintain acid sites needed to perform hydrocracking, isomerization and cyclization conversion reactions. Accurate measurement and control of moisture is a technical challenge in the operation of catalytic reformer units. During normal operation the moisture content of the reactor feed is controlled at a low level (5 to 50 ppm). Refineries try to avoid excessive moisture levels which can poison the catalyst. Catalyst activity in an SRR gradually decreases over time as coke is deposited on the catalyst. The catalyst beds in an SRR are periodically regenerated to restore catalyst activity. The SRR is taken off line and regeneration is performed by in-situ oxidation 36 | Automation INSIGHT! | SEPTEMBER 2015
once every 6 to 24 months. Monitoring moisture concentration during regeneration and subsequent drying of the catalyst upon reintroduction of the feed gas is important for optimizing catalyst performance and life. During regeneration moisture is measured at higher levels (up to 1,000 ppm) to monitor the progress of catalyst decoking. The expensive catalyst can be regenerated 3 or 4 times before it must be replaced. The spent catalyst is returned to the manufacturer to recover the platinum or rhenium metals. One of the ways to monitor H2O levels for optimal catalyst activity and during in-situ regeneration is by measuring the water content in SRR hydrogen recycle gas.
Problems with Traditional Moisture Measurements
Historically, refineries have relied on electrochemical moisture sensors to monitor H2O in hydrogen recycle streams. While electrochemical sensors are relatively simple instruments they have a number of deficiencies when employed for measurements in harsh process gas applications such as SRR hydrogen recycle streams. The major problem with moisture analyzers using aluminum oxide (Al2O3) sensors is that the sensor element is in direct contact with the process gas and
PROCESS ANALYZERS
(Figure 1. H2O Measurement in the Hydrogen Recycle Stream of an SRR)
entrained contaminants. In the case of SRR hydrogen recycle streams this means the sensor element is directly exposed to HCl, H2S and other contaminants that corrode and destroy the sensor requiring frequent replacement. To compensate for the high rate of sensor failure many refineries have installed redundant sensors as backups in case one electrochemical analyzer stops working. Electrochemical sensors and quartz crystal microbalances have problems beyond corrosion damage from direct contact with the process gas. Both techniques are inferred measurements where physical contact with the sample induces a change in capacitance or quartz crystal oscillation. These techniques cannot always distinguish H2O from other compounds present in a gas stream resulting in inaccurate readings. Both types of analyzers are also slow to respond to changes in moisture concentration due to wet-up and dry-down times.
Tunable Diode Laser Technology
Many refineries are transitioning away from older measurement technologies to Tunable Diode Laser (TDL) analyzers. TDL analyzers are specifically designed to measure moisture and other analytes (H2S, C2H2, NH3, and CO2) in process gas streams. In operation, process gas from a sampling probe is introduced to the sample cell of the TDL analyzer. A window isolates the laser source and solid state detector components from the process gas. This design allows measurements to be performed with absolutely no contact between the process gas (and entrained contaminants) and critical analyzer components. The laser emits a wavelength of near-infrared (NIR) light that
(Figure 2. TDL Analyzer for Operation in Refinery Locations with Hazardous Area Safety Classifications)
is selective and specific for measurement of water molecules which absorb the light and allows calculation of the moisture concentration. The response time of TDL analyzers to changes in analyte concentration is seconds versus several minutes or longer for other analyzers.
Summary
Refineries strive to optimize the activity, cycle time between regeneration, and operational life of SRR catalysts. On-line, realtime moisture measurements in the SRR hydrogen recycle gas stream help refineries assess catalyst condition during normal process operation and in-situ catalyst regeneration. Refineries have recognized the advantages of TDL analyzers in this challenging application and adopted the technology to upgrade their SRR process monitoring capability. SEPTEMBER 2015 | Automation INSIGHT! | 37
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INTEGRATED OPERATIONS
Essentials of the connected enterprise
The case for the connected enterprise
The global population recently rounded 7 billion on its way to 8 billion by 2030. And an estimated 70 million of those souls will enter the burgeoning middle class each year, placing an ever greater demand on supplies of energy, water, food, and other manufactured goods. To meet these demands, manufacturers and other industrial operations must become ever more productive even as they wring inefficiencies out of their processes and supply chains. Today’s production systems already throw off data at an unprecedented rate. But the sheer volume of data—coming as it does from isolated, disparate sources—is as likely to overwhelm as it is to inform. Fortunately, advances in communications and computing technology as exemplified by the rise of the Internet of Things, Big Data & Analytics, and the Cloud promise to enhance the creation of what Rockwell Automation refers to as The Connected Enterprise. Better information sharing can simultaneously drive better decision making, expose process inefficiencies, and facilitate compliance and best-practices collaboration. Indeed, organizations that embrace what’s possible with today’s rapidly advancing computing and communications technology 40 | Automation INSIGHT! | SEPTEMBER 2015
stand to uncover new competitive advantage, even as those who do not face escalating competitive risk. The idea of an industrial enterprise that is integrated from top to bottom and out across its distributed value chains has been with us for decades. Even as the first microprocessorbased controllers and software applications began to seep into every corner of the industrial operation, the inkling began to take hold that smartly integrating the information otherwise stranded in these isolated devices and systems could lead to dramatic performance improvements. But building these custom, point-to-point linkages was both expensive and labor-intensive. Further, they proved relatively brittle and inflexible. As a result, only the highest priority integration projects were undertaken, and integrated systems remain more the exception than the rule across industry. For example, in a recent survey by LNS Research, manufacturers still cite disparate systems and data sources second only to lack of collaboration across departmental functions as top operational challenges. Today, technology is finally poised to catch up with the longstanding promise of integration to expedite The Connected Enterprise. Ever smarter, more capable digital devices are
INTEGRATED OPERATIONS converging with increasingly pervasive networks and unprecedented, on-demand computing power. In the broader technology arena, these umbrella forces are variously classified as the Internet of Things, Big Data & Analytics, Cloud Computing and Virtualization. But for most industrial organizations, the idea of terabytes of proprietary data instantly flowing to anyone anywhere is not necessarily a comforting thought. Enter Rockwell Automation and its vision for The Connected Enterprise. In the balance of this Essentials report, we’ll explore in greater detail several important dimensions of a Connected Enterprise: a robust network infrastructure based on standard Internet/Ethernet protocols; an inventory of “working data capital� that acknowledges the contextual information needs of people and systems; and network security in the form of ongoing threat management practice, policy and culture across all levels of the organization and across its supply chain.
A Common network infrastructure One characteristic of The Connected Enterprise is a converged control and communication
architecture based on standard Ethernet and Internet Protocol (IP) technology. This does not mean that the entire site is plugged into one common network. Rather, a common architecture based on these standards makes it far more straightforward for organizations to securely integrate and manage advantageous information flows across the entire extended enterprise. Many devices being used in industrial automation already are IP-enabled, and the IP connectivity of many more devices from the non-industrial world stand to be leveraged by adopting an Ethernet-based infrastructure. These technologies, such as tablets, video cameras and RFID readers, provide many opportunities for greater productivity, innovation and collaboration. To take advantage of these devices, operations must allow these machines, equipment and non-industrial devices to communicate with each other via a standard, IP-centric infrastructure.
The Ethernet Industrial
Protocol (EtherNet/IPTM) was created to support this interoperability and to ensure seamless enterprise-wide connectivity within a single infrastructure. In contrast, proprietary, or purpose-built network technologies often require gateways or other specialized translation devices, restricting and complicating network architecture. Plus, they introduce custom coding and legacy support issues. Because EtherNet/IPTM complies with IEEE 802.3 and TCP/UDP/IP standards and conventions, it also leverages
INTEGRATED OPERATIONS readily available, off-the-shelf infrastructure components. This helps operations and IT professionals collaborate on deploying and maintaining a secure, reliable and robust network infrastructure within the enterprise and throughout the industrial environment. Using standard Internet and Ethernet protocols like EtherNet/IPTM helps tie operation data together with the rest of the enterprise. It also provides a future-proof communication backbone for pervasive growth in Internet-enabled devices. As EtherNet/IPTM continues to become more universally deployed in both discrete and process automation environments, Connected Enterprises are beginning to realize the business value of the right information delivered to the right decision-maker at the right time. Indeed, new visibility into production data and supplychain information offers the next wave in competitive differentiation.
Working Data Capital
Clearly, the era of Big Data has arrived, and industrial operations lead the way in terms of sheer volume. Simply capturing that data to storage is perhaps a good start, but without context it remains meaningless. Industrial organizations on their way to becoming Connected Enterprises should address their data strategically. Capturing more data isn’t necessarily better. Instead, they should target the data that’s most relevant, starting with their most critical assets. They should ask searching questions such as “What could the right data tell us if we had it?” Indeed, the true value of Big Data lies not in the data itself, but in what analytics applied to the right data reveal. In this way, raw information can be transformed into “working data capital,” and put to work on behalf of The Connected Enterprise. Once identified and/or derived, this working data capital needs to get to the systems and/ or decision- makers who can put it to best use. Three particularly relevant technologies that are enabling more efficient analysis, communication and visualization of working data capital to be scalable to The Connected Enterprise are virtualization, cloud computing and mobility. In short, virtualization and cloud computing entail the relocation of software applications from local servers to an on-premise or off-site datacenter. This can reduce local IT footprint together with associated maintenance and energy costs. From an operational standpoint. 42 | Automation INSIGHT! | SEPTEMBER 2015
uch hosting strategies are ready-made for supervisory applications such as remote asset management, performance and energy monitoring, and supply chain collaboration. Virtualization, in which application software is effectively abstracted from its operating system and hardware specifics, is a companion technology to cloud computing on the uptake in industrial environments. While today’s cloud datacenters are built from the ground up on virtualization technology, locally hosted software and systems also can benefit from the lower hardware, energy and maintenance costs of virtualized solutions. On the mobility front, more than 60 percent of businesses already allow employees to bring devices to work, according to the Manufacturing Enterprise Communications Research Services. In fact, five terabytes of data were viewed on mobile devices in the last year.
INTEGRATED OPERATIONS
And while accessing industrial data on any tablet or smartphone is a key benefit of mobility, the ability of information and workers to be “mobile” and access applications on the go is just as benificial.
Security throughout
While the proliferation of Internet-enabled devices and the deployment of standard Ethernet across The Connected Enterprise promise tremendous benefit, this convergence also brings security concerns to the fore. Networks, as well as assets, intellectual property and site availability all need to be secured from potential threats—both accidental and intentional. What’s needed is an active security culture that permeates every person, policy and procedure in The Connected Enterprise. Security can’t be tacked on; it must be woven into the network infrastructure, new and legacy control systems, machinery & equipment, industrial devices and enterprise-level systems. The breadth of threats that exist today combined with a constant stream of new threats requires that security in The Connected Enterprise be robust and capable of stopping threats on multiple fronts. As a result, a “defense-in-depth” security approach that addresses both internal and external security threats is required. Defense-in-depth security encompasses
physical, network, computer, application and device security. A defense-in-depth strategy is recommended in the IEC 62443 standard series (formerly ISA 99), the National Institute of Standards and Technology (NIST) Special Publication 800-82 and the U.S. Department of Homeland Security’s external report INL/ EXT-06-11478. For its part, Rockwell Automation continues to address industrial security systemically throughout its Integrated Control and Information portfolio, adopting specific design-for-security development practices into its product and system development processes. Further, it continues to expand the physical, cyber and intellectual property protection mechanisms in its control products, and has cultivated relationships with network infrastructure vendors like Cisco® to enhance its active threat monitoring capabilities and to provide industry with guidelines, recommendations and practical advice for reducing operational risk. Fortunately, the same technologies that characterize The Connected Enterprise also provide the means to actively protect it—from corporate servers all the way down to controllers and other connected devices on the remotest edge of the enterprise network.
About the control essentials series
The mission of the Essentials series is to provide industrial automation professionals with an up-to-date, top-level understanding of a range of key automation topics. Our intent is to present essential engineering concepts in a practical, non-commercial fashion, together with a review of the latest technology and marketplace drivers—all in a form factor well suited for onscreen consumption. We hope you find this edition useful. Check in at ControlGlobal.com/Essentials for other installments in the series. SEPTEMBER 2015 | Automation INSIGHT! | 43
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ASSET PERFORMANCE AND PRODUCTIVITY ENHANCEMENTS
Asset Performance and Productivity Management Author: Dinesh Nautiyal
46 | Automation INSIGHT! | SEPTEMBER 2015
ASSET PERFORMANCE AND PRODUCTIVITY ENHANCEMENTS
Asset performance management enables the user to predict and present failures by analyzing existing data and finding critical information that is currently not being used. The following are the qualifiers which can give an insight on the performance of a system.
Performance Qualifiers
• Excessive unplanned downtime • Low asset utilization • Unknown asset utilization • Scrapping The following are some of the core processes for an Asset management system: • Monitoring of energy consumption – Increased energy consumption gives an early warning on asset problems and is a key predictive maintenance criteria. • Identification of Assets, components and areas that are underperforming and implementing corrective solutions. • To keep a track on the budgets and deviations and if found should be analyzed. • Follow-ups on the assets investment and required corrective actions to be taken. Asset performance management is not only a generation of a report or logging of an alarm, rather it is to find out what really is important to the system and an assurance that there is somebody who is acting on the information generated.
Following are the key application areas for a performance management system: • Data collection from SCADA and PLC systems and integration to higher level systems – Alarms with asset information and conditions are generated and automatic work orders can be generated for the corrective action. • Alert management • Report generation - The business processes needs to be identified and reports should be generated to manage the processes and asset efficiently. Whether the production environment have one or hundreds of assets, the present day EMI (Enterprise Manufacturing Intelligence) gather data from any source and any format, storing it in a secure database for subsequent processing, distribution and presentation.
The performance key benefits are: • Automatic registration and classification of downtimes. • Scrap registration • Calculation of OEE and other KPIs • Equipment and product effectiveness correlation. • Comprehensive reporting.
About the Author
Nautiyal is a Technical Manager at Telinstra FZCO, a leading system integrator in automation, instrumentation and electrical services and solutions. SEPTEMBER 2015 | Automation INSIGHT! | 47
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FUNCTIONAL SAFETY AND SIS
Fire & Gas Mapping Advances Fire and gas modeling is continuing to evolve to benefit the industrial requirements.
Author: Sean Cunningham, Kenexis
The practice of fire and gas mapping has become common place for industrial facilities concerned about fire, combustible gas and toxic gas hazards. Fire and gas mapping is a method of specifying layo¬¬¬uts of detectors using complex computer models to better understand the probability of successful detection within a monitored area. Historically, the task of determining detectors layouts has been performed using expect judgment and heuristics. Fire and gas mapping provides the design engineer with a consistent, repeatable method for determining how many detectors are required, where they should be located, and why. In recent years there have been many advances in the practice of fire and gas mapping, most notably the use of 3D cad models as inputs to the mapping process. This article explores some of the complications that arise when using traditional fire and gas mapping methods which 3D cad models and details the latest improve in optical flame detector mapping, referred to as the fire plume model. Import of 3D models for fire and gas mapping is an advancement over the traditional methods of developing simplistic 3D models from geometric primitives which can be a time consuming task. While importing 3D models directly provides benefits in timesavings it also introduces some complexity when it comes to the fire models used to analyze detector coverage, particularly when using the geographic coverage methodology.When working with a traditional “geometric primitive” 3D model, it is common practice to only include objects which are large enough to obstruct a fire of a threshold size of concern (e.g. a 0.3m x 0.3m hydrocarbon pool fire). As a result, small obstructions such as small bore piping, instrument tubing, conduit, etc. are often not included in the 3D model. Excluding these objects is appropriate and does not result in an overestimation of the achieved coverage because of a conservative assumption which is inherent to the “point source fire model” used by most fire and gas mapping software. 50 | Automation INSIGHT! | SEPTEMBER 2015
The Point Source Fire Model
In the point source fire algorithm, a fire is assumed to occur at a single point in space (an infinitely small fire, radiating infinitely hot). This assumption results in a conservative calculation of coverage because, as we all know, a fire has volume. Making the assumption that a fire occurs at a single point in space is conservative even for the smallest fires of concern. This is why exclusions for minor obstructions when using the point source model is not only standard practice, but is often required to achieve an acceptable degree of coverage. Let’s look at an example. The images below show the field of view for a single optical flame detector. In both images, the field of view of the detector is shown by the yellow region. In the image to the left you’ll notice a small green obstruction running horizontally across the image. This obstruction represents a 75mm diameter pipe. In the image to left, the field of view of the detector appears uninterrupted because your perspective is from the exact
FUNCTIONAL SAFETY AND SIS location of the detectors lens. However, when the image is rotated and the pipework is shown in wireframe, as shown on the right, you can clearly see that the point source coverage algorithm has predicted an area of uncovered space directly behind the pipe from the perspective of the detector. The point source model has predicted that a fire centered at any location along the red obstructed region caused by the pipe will be undetectable. However, we know that in reality fires are not infinitely small point sources; we know that fires have volume. Intuitively we know that a 75mm diameter pipe will not significant impede the ability for a detector to detect a 300mm diameter pool fire, this is why exclusions of such object is common practice. When working with 3D models, what you will find is that operating with the conservative assumptions of the point source algorithm can result in overly conservative results because of the cumulative effect of these small diameter obstructions. For this reason, it is often necessary to implement a coverage algorithm which accounts for the volume of a fire. This algorithm is referred to as the “plume fire model”.
The Plume Fire Model
In the plume fire model, the fire is assumed to be emitting thermal radiation equally over its entire surface. When the fire geographic coverage algorithms are run, the tool will calculate the fraction of the fire surface which is observable from the fire detector. In doing this, the fraction of the fires total radiant heat output which is viewable from the detector can be determined. This is shown in the images below, where a grid has been superimposed onto
the plume (far left). Adding a small diameter pipe between the detectors point of view and the plume will obstruct a fraction of the plume which is visible (middle). This fraction of the plume will then be ignored by the fire coverage algorithms. After this obstructed area is accounted for, the tool can determine whether a fire is detectable based on the remaining observable surfaces of the plume (far right). Now let’s look at the plume fire algorithm in action (Above images). Just as before, we’ve introduced a 75mm diameter pipe into the field of view of an optical flame detector. However, now the area directly behind the pipe is predicted as an unobstructed region. Why? This is because the volume of the fire is sufficient such that a fire centered at a location directly behind the pipe will result in a plume which is largely still visible to the detector. While the pipe may be obstructing 10%-15% of the fire surface, the detector is still receiving sufficient thermal radiation to cause the detector to reach an alarm state.
SEPTEMBER 2015 | Automation INSIGHT! | 51
FUNCTIONAL SAFETY AND SIS Real World Application
The image to the right is a real world example of 3D fire and gas mapping analysis where the differences between the point source and plume fire models are apparent. The following images are of a manifold deck on an offshore facility. As you can see in the 3D view below, there is a significant amount of minor obstructions in the area being modeled. The below images display a plot view of the achieved fire detector coverage utilizing both the point source model and the plume model. The top image displays the achieved coverage utilizing the point source model. The bottom image displays the results using the plume fire model with the 1m x 0.3m x 0.3m plumed defined above. The areas in green are covered by 2 or more detectors, areas in yellow are covered by a single detector and areas in red are uncovered.
Conclusions
Use of the plume fire model is highly recommended when performing fire and gas mapping using imported 3D CAD models which contain a high degree of detail. The effect of changing between the point source model and plume fire model are most pronounced when working with 3D models where the field of view of detectors are highly obstructed by small diameter piping or other minor obstructions. Use of the plume fire model is not recommended for fire and gas mapping studies where simplified 3D models are developed from geometry primitives, unless those models are developed with a high degree of detail. In studies with simplified 3D models, use of the plume fire model could result in a non-conservative prediction of detector coverage. 52 | Automation INSIGHT! | SEPTEMBER 2015
FEATURED PROJECT PROJECT NAME:
BAPCO - Bapco Modernization Program (BMP) Name of Client:
BAPCO - Bahrain Petroleum Company
Budget ($ US):
6,000,000,000
Facility Type:
Refining
Sector:
Refining
Status:
FEED
PMC: Main Contractor
Technip Chevron Lummus Global
Location
Sitra
PROJECT BACKGROUND Bahrain plans to add 100,000 barrels per day (bpd) of new refinery capacity to its Bapco plant beyond 2016. The Bapco refinery currently has
a capacity of around 260,000 bpd. The refinery expansion plan is contingent on boosting the capacity of a pipeline that brings 220,000 bpd of crude to the plant from Saudi Arabia.
PROJECT STATUS 16 Jul 2015
Bapco receives one bid only for the Hydrogen Plant Engineering Design Package. The bid has a value of $1.32 m submitted by Technip (USA). UOP is the only bidder for the New Train in the Kerosene Merox Unit. UOP submitted a bid worth $585,59 m
12 Jul 2015
Baco is to receive on 15 July proposal for the following contract: - Engineering Design Package (EDP) for the Hydrogen Plant - Engineering Design Package (EDP) for a New Train in the Kerosene Merox Unit (KMU)
07 Jun 2015 CH2M Hill has been awarded the FEED contract for the No.3 API separator unit. 09 Apr 2015 Bids for a consultancy contract to provide the implementation of lead and future analysis of the modernization program are due on 16 April. 18 Jan 2015
The project was at the FEED stage. The FEED study will be completed by late 2015. Bapco will make a final decision on the expansion project by early 2016.
28 Dec 2014
Bapco has received one single proposal for the Engineering design package for integrate crude and vacuum distillation unit CDU/VDU. The bidder is Technip Italy with a proposal worth $1.385 million.
24 Dec 2014
The following companies have bid for the FEED contract to replace No.3 API separator: CH2M Hill Inter. - $.887 m Simeco - $.9 m WorleyParsons - $.953 m Engineers India - $1.137 m JCC Gulf Inter. $1.510 m Technip - Suspended
16 Oct 2014 The financial bids for the legal Advisor contract were opened. The result was as follows: - Linklaters $.810 m (Suspended) - Allen & Overy (suspended) - Shearman & Sterling - $1.957 m Oct 2014
A JV of CB&I and Chevron has been awarded a contract valued at $100 m to provide license of its LC-FINING and ISOCRACKING technologies and to prepare the engineering design for the new residue hydrocracking and vacuum gasoil hydrocracking units.
54 | Automation INSIGHT! | SEPTEMBER 2015
FEATURED PROJECT
PROJECT STATUS 10 Jul 2014
Bapco has approved the bid submitted by Freshfields Bruckhaus derringer. The other bids were suspended.
10 Jul 2014
The following 7 firms have bid for the tender to provide legal Advisory services. Shearman & Sterling Norton Rose Fulbright M.E Baker & McKenzie Ltd. Freshfields Bruckhaus deringer Linklaters Allen & Overy Clifford Chance
06 Jul 2014
Bapco has issued a tender for a tender for the legal Advisors contract for the Modernization Program. 10 July is the bids submission deadline.
03 Jul 2014
Technip has been awarded the $55.9 million FEED contract. The FEED is expected to be completed in March 2016.
08 May 2014
Bapco received the following bids for Technology & Engineering Design Package Licensor for new Sulfur Process Units: -Jacobs Nederland - $2.9 m(Suspended) -CB&I - $310,000 and $2.16 m -Worley Parsons - $610,000 and $1.1 m -Black & Veatch - $1.45 m
14 Apr 2014 The Engineering design Packages (EDPs) of phase 1 will be prepared by selected Technology licensors. The EPC work is expected to start in 2016. The contracting strategy for phase 1 will be finalized soon. The project is scheduled for completion by 2020. 13 Mar 2014
2 bids were submitted for the Technology and Engineering Design Package (EDP) Licensor for the Hydro-Cracking Unit. The bidders are Chevron Limmus - $2.3 million and UOP (suspended).
23 Jan 2014
4 firms have bid for a contract to provide the design for the Diesel Hydrocracking Unit. The firms are: Axens - $1.2 m Haldor Topsoe - $10.8 m UOP Chevron Lummus Global - sumbitted 6 proposals as follows: $.4 m $.68 m $.7 m $1.5 m $2.92 m $2.95
16 Jan 2014
5 bids were submitted for the FEED contract. The bidders are: - JGC Corporation/ KBR - Technip (Italy) - $63.5 m - CB&I (Netherlands) - $56.3 m - WorleyParsons (Bahrain)/WorleyParsons Int. $105m $111m, $114m (all are suspended) - Bechtel Ltd. - $49
05 Dec 2013
2 contractors have bid for the Engineering Design Package (EDP) Licensor for New Process Units. The bidders are: - Chevron Lummus Global - $3.5 million - AXENS - $6 million
10 Oct 2013 The proposals for the Bapco Modernization Program (BMP) Lender's Independent Market Consultant contract were submitted by 2 consultants, IHS Global and Nexant Ltd.. Both proposals were suspended. 12 Sep 2013 The bids for the FEED and PMC contract were submitted, the bidders are: - Foster Wheeler - $189 million - Engineers India - $124 million 28 Mar 2013
Bapco received Solicitation of Interest from 12 consultants for the FEED and PMC contract for the project. The consultants are: CB&I Flour Technip JGC Bechtel Foster Wheeler Worley Parsons KBR Engineers India Mott Macdonalds Jacobs Engineering
14 Jan 2013
HSBC and BNP Paribas have been appointed as joint financial advisers for the project.
15 Nov 2012
The financial advisory contract be awarded soon.
SEPTEMBER 2015 | Automation INSIGHT! | 55
FEATURED PROJECT
PROJECT STATUS 11 Oct 2012 4 bids were submitted for the financial advisory contract. The bidders are: BNP Paribas $2.4 million JP Morgan - $2.4 million HSBC - $3 million Deutsche - $3.6 million BNP Paribas has already completed a three month assignment on the project. 10 May 2012
The feasibility study was ongoing. The FEED-ITB will be issued in Q3 2013.
Feb 2012
A project execution plan (PEP) is being prepared, technology selection is proceeding and options for financing are under review. The PEP and technology selection will be completed in 2012.
Dec 2011
Bapco has received one bid for the Refinery Master Plan Unit Detination Study. The only bid was from Chevron Lummus Global submitted of $2.3 million.
Nov 2011
The pre-feed study, conducted by Chevron Lummus Global has been finalized. Bapco is currently awaiting approval from NOGA for the plan.
Aug 2011
BNP Paribas was appointed as the financial adviser.
Jul 2011
2 banks were shortlisted for the financial adviser contract. The banks are: HSBC (UK) BNP Paribas (France)
Jun 2011
Decision Processes Incorporated was awarded a contract for plan study Decision Risk Analysis (DRA), and Nexant Limited was awarded a contract for Due Diligence for the refinery master plan study.
May 2011
Bapco is reconsidering its plans for the refinery expansion. The initial plans to raise the production up to 500,000-600,000 b/d of crude oil are now considered to be reduced to either 350,000-b/d or 450,000-b/d.
Mar 2011
The following 4 banks have submitted proposals for the financial adviser contract. JP Morgan (US) Citigroup (US) HSBC (UK) BNP Paribas (France)
Sep 2010
Chevron Lummus Global is currently working on different models aimed at enhancing oil production capacity to 500,000 b/d or 600,000 b/d.
Oct 2009
Bapco has awarded a consultancy deal to the USA's Chevron Lummus Global for the master plan. Chevron Lummus won the contract with a bid of $1.5 million despite US rival UOP submitting a lower bid of $1.35 million.
02 Jul 2009
2 American companies have submitted their bids for a contract to develop the masterplan. The bidders are: - Chevron Lummus Global (US) - $1.46 million - UOP (US) - $1.35 million
May 2009
Bapco has concluded preliminary feasibility studies for its refinery expansion project.
Apr 2009
Bahrain has announced that it plans to go ahead with its long-term plan to boost capacity at its Sitra refinery.
56 | Automation INSIGHT! | SEPTEMBER 2015
FEATURED PROJECT
PROJECT SCOPE Bahrain plans a $6 billion expansion at its Sitra refinery, which would take capacity to between 500,000 and 600,000 barrels per day (bpd) up from around 267,000 bpd. The project calls for a revamp of the refinery’s five crude distillation units by replacing some ageing units and having only one or two large units. Bapco would also like to build a unit to convert heavy fuel oil into lighter transport fuels. The scope of work includes: • Hydrogenation unit • Crude distillation units • Splitter *Naptha hydrotreater • Distillate hydrotreater • Sulphur recovery unit • Sour water stripper • Handling facilities • Offistes & utilities
PROJECT SCHEDULE Feasibility Study
1Q-2009
FEED ITB
1Q-2013
FEED
3Q-2014
EPC ITB
2Q-2016
Engineering & Procurement
2Q-2016
Completed
2Q-2020
The scope of Technip’s work involves converting bottom of the barrel components into higher-value products. Approximately 220,000 bpd of oil is currently provided by Saudi Aramco, while 40,000 bpd is coming from Bahrain’s own reserves. This means the company will look to develop the residue conversion unit (RCU) first as it will process heavier crude types into lightergrade products. Bapco is believed to be keen to develop the RCU first then use the money generated to fund the remaining work. A huge bulk of the additional capacity will be middle distillates or diesel fuel.
PROJECT FINANCE Bapco is the project client.
* Information provided by DMS Projects Matrix. For more details, please contact us T:+973 1740 5590, F: +973 1740 5591, Email: info@dmsglobal.net Log onto www.DM SGLOBAL.net SEPTEMBER 2015 | Automation INSIGHT! | 57
PROJECT LISTING
Bahrain PROJECT
FACILITY
BUDGET ($ US)
STATUS
AAJ Holdings Company - Marina West
Mixed-Use Development
270,000,000
Construction
Abahusain Fiberglass - Fiberglass Plant
Fiberglass
200,000,000
EPC ITB
Al Baraka Banking Group - ABG Towers
Office Buildings
100,000,000
Construction
Al Mannai Group - Sukoon Tower
Residential Development
146,000,000
Construction
Alba - Aluminium Potline 6 Expansion
Aluminium Potline
2,500,000,000
Feasibility Study
Alba - Power Plant
Power Plant
1,000,000,000
EPC ITB
Albilad Real Estate - Water Garden City
Mixed-Use Development
975,000,000
Construction
Amlak International Investment - Bahrain Marina
Mixed-Use Development
250,000,000
PMC
BAC - Bahrain International Airport Modernization Program - Baggage Handling System
Airport
50,000,000
EPC ITB
BAC - Bahrain International Airport Modernization Program - MRO Hangar
Airport
200,000,000
PMC ITB
BAC - Bahrain International Airport Modernization Program - New Aviation Fuel Farm & Fuel Hydrant
Oil Storage Tanks
200,000,000
FEED ITB
BAC - Bahrain International Airport Modernization Program - Overview
Airport
900,000,000
EPC ITB
BAC - Bahrain International Airport Modernization Program - Passenger Loading Bridges
Airport
50,000,000
EPC ITB
BAC - Bahrain International Airport Modernization Program - Terminal Building
Airport
200,000,000
EPC ITB
Bahrain Defence Force - Cardiology Centre
Medical/Health Facilities/Spa
104,000,000
Construction
Bahrain Defence Force - King Hamad University Hospital (KHUH) - Cancer Centre
Medical/Health Facilities/Spa
82,000,000
Construction
Banader Hotels Company - Rotana Hotel
Hotels
79,600,000
Construction
Banagas - Central Gas plant 3
Gas Treatment Plant
500,000,000
EPC ITB
Bapco - A-B Pipeline
Oil
350,000,000
EPC ITB
BAPCO - Bapco Modernization Program (BMP)
Refinery
6,000,000,000
FEED
BAPCO - Bapco Modernization Program (BMP) - Residue Conversion Unit
Refinery
800,000,000
FEED
Diyar Al Muharraq Development - Diyar Al Muharraq Housing Development
Mixed-Use Development
500,000,000
Construction
Diyar Al Muharraq Development - Infrastructure package
Mixed-Use Development
50,000,000
Engineering & Procurement
Diyar Al Muharraq Development - Overview
Mixed-Use Development
3,200,000,000
Construction
Edama - Al Jazayer Beach Development
Theatre/Entertainment/Leisure Facilities
1,200,000,000
PMC ITB
Edama - Al Jazayer Beach Development - Fairmont Hotels & Resorts
Beaches and Resorts
80,000,000
Design
EWA – New System Control Centre (SCC)
Utilities
120,000,000
On Hold
EWA - 220kV and 66kV Transmission Development Scheme 2007 - 2012
Power Transmission Lines
330,000,000
Construction
EWA - 220kV and 66kV Transmission Development Scheme 2012 - 2016
Power Grid
400,000,000
Design
EWA - 400kV Transmission Development - Cable Works Phase 2- Package B
Power Transmission Lines
110,000,000
EPC ITB
EWA - 400kV Transmission Development - Cables & Accessories
Utilities
60,000,000
EPC ITB
EWA - 400kV Transmission Development - Overview
Power Transmission Lines
1,000,000,000
EPC ITB
EWA - 400kV Transmission Development - Substation Switchgear and Civil Works
Substations
100,000,000
EPC ITB
EWA - 400kV Transmission Development - Transformer and Reactor
Transformers
70,000,000
EPC ITB
EWA - North Town Power Transmission - Phase 3
Substations
179,000,000
Feasibility Study
EWA - Three New Power Plants
IPWP (Independent Power & Water Project)
5,000,000,000
Feasibility Study
58 | Automation INSIGHT! | SEPTEMBER 2015
PROJECT LISTING
Bahrain PROJECT
FACILITY
BUDGET ($ US)
STATUS
EWA - Water Transmission Development Project - Pipeline South Installation Works
Water
11,000,000
Construction
EWA - Water Transmission Development Project - Pipeline West Installation Works - PIW
Water
20,000,000
Construction
EWA - Water Transmission Development Project - Water Station North
Distribution Network
60,000,000
Construction
EWA - Water Transmission Development Project -Water Station Elevated Services Reservoirs
Water Storage Tanks
50,000,000
Construction
EWA - Water Transmission Development Project 2009-2012 Pipeline North Installation Works - PIN
Water
15,000,000
Engineering & Procurement
Fouad Hussain Mohammed Showaiter - Muharraq Grand Park
Theatre/Entertainment/Leisure Facilities
63,200,000
Engineering & Procurement
Garmco - Re-melt and Casting Facilities Expansion
Aluminium Smelter
50,000,000
Engineering & Procurement
GBCORP - Marsa Al Seef Project
Mixed-Use Development
2,500,000,000
Design
GCC Railway Network
Railway
4,000,000,000
Feasibility Study
GPIC - Ammonia Plant Expansion
Ammonia
600,000,000
On Hold
GPIC - Urea Plant Expansion
Urea
900,000,000
On Hold
Gulf Biotech - Insulin Factory
Pharmaceutical Factory
93,000,000
Engineering & Procurement
Gulf Holding Company - Villamar @The Harbour
Residential Development
650,000,000
On Hold
Ithmar Bank - Dilmunia Health Island
Mixed-Use Development
1,600,000,000
Engineering & Procurement
Kerzner International Holdings - One&Only Resort
120,000,000
Construction
Service Centres
130,000,000
EPC ITB
Manara Developments Company - Wahat Al Muharraq
Mixed-Use Development
106,000,000
Construction
Ministry of Finance - Waste-to-Energy Plant
Waste Recycling
1,000,000,000
EPC ITB
Manara Development - Investment Gateway - Bahrain - Phase 1
Ministry of Health - King Abdulla Medical City
Medical/Health Facilities/Spa
260,000,000
Design
Ministry of Housing - NBNT Primary Sewerage and Treated Sewage Effluent Network
Sewerage Treatment
150,000,000
EPC ITB
Ministry of Housing - NBNT Sewage Treatment Plant and Long Sea Outfall
Sewerage Treatment
100,000,000
EPC ITB
Ministry of Housing - Southern Governorate Housing Development
Residential Development
220,000,000
Construction
Ministry of Municipalities and Urban Planning - Howar Island Solar Power Plant
Solar
100,000,000
Feasibility Study
Ministry of Transportation - GCC Railway Network - Bahrain - Saudi Link
Railway
4,500,000,000
Feasibility Study
Ministry of Transportation - National Railway
Railway
2,000,000,000
Feasibility Study
MOH - East Hidd - Phase 1
Residential Development
72,000,000
Construction
MOH - East Hidd - Phase 2
Residential Development
45,000,000
EPC ITB
MOH - North Bahrain New Town (NBNT)
Mixed-Use Development
5,000,000,000
Construction
MOT - Bahrain Integrated Transit Lines
Railway
8,120,000,000
On Hold
MOT - Bahrain New Airport
Airport
3,000,000,000
On Hold
MOW - Al Fateh Highway Upgrade
Roads
50,000,000
Design
MOW - Alba Roundabout Intersection
Roads
96,000,000
EPC ITB
MOW - Manama North Shore Redevelopment
Roads
500,000,000
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 SEPTEMBER 2015 | Automation INSIGHT! | 59
DMS CSR
DMS Continuously Makes A Choice for Channge Following the success of the ISA Automation event, held in Abu Dhabi on the 26th and 27th of May, DMS Global is proud to announce that they have donated a further $3,000 to the Choice to Change (C2C) Foundation. DMS Global, a marketing solution provider for the energy industry, has a long-standing relationship with the C2C Foundation, utilising the full spectrum of their business skills to promote the provision of access to primary education for underprivileged children in Bangladesh. The level of commitment DMS shows these underprivileged children is remarkable, and is underpinned by a belief that every child deserves access to basic education. According to the Millennium Development Goals, as of 2015, enrolment in primary education in developing regions has reached 91%, compared to 83% in 200, and DMS is proud to have contributed to effecting such positive change. Established in July 2010, C2C has helped hundreds of children in a developing nation to gain access to vital education, and each member 60 | Automation INSIGHT! | SEPTEMBER 2015
of DMS is delighted to contribute to this worthy cause. Two schools were opened in the slum areas of Dhaka to provide vital educational facilities to the regions’ youth. Sustainable CSR initiatives are critical to DMS’ vision, which is demonstrated through regular charitable donations. DMS is dedicated to supporting both local and international charitable causes. From the proceeds of the Project Management Institute (PMI) event in 2014, DMS donated $3,000, split between C2C and an autism nursery in Bahrain. C2C used their share to provide a bus service to transport children safely from the slums to school. The proceeds of the ISA Saudi Arabia Conference and Exhibition in 2013 were split between C2C and Al Qatif Autism Centre, each receiving $1500. The Al Qatif Autism Centre is based in the Eastern Province of KSA. It encourages children with special needs to participate in daily activities and provides them with tailored educational services. The staff of the centre understand the need to integrate the autistic children’s families into their activities to enhance the quality of their service, with the ultimate outcome of providing an excellent quality of education. During a visit by President and CEO Mohammed Loch to the C2C schools in Bangladesh, DMS sponsored two Iftar Dinners for the children of the C2C schools. Over 600 children and their families enjoyed Iftar with DMS during the holy month of Ramadan last year.
DMS CSR
About DMS Global
Headquartered in Bahrain, DMS Global has been the region’s leading business intelligence and marketing solutions provider to the energy sector since 2000. Our business expertise is diversified across, global projects tracking, events management, industryspecific publishing and digital & multimedia production. DMS manages one of the most comprehensive project databases in the world and has a unique access to key decision makers and experts across multiple disciplines. www.dmsglobal.net
About C2C
The Choice To Change (C2C) was founded by Eva Kernova, and Sunil Baroi, in July 2010. They chose to change the lives of poverty-stricken children in the slums of Dhaka by paving an educational pathway for them to follow. Attaining any type of formal education would have been impossible for these underprivileged children without the help of such a non-profit organisation. The school now comprises of 148 children, 9 teachers headed by headmaster, social worker, a nurse and a head-cook. In 2013 DMS Global partnered with C2C to cover the administration and marketing costs as well as the responsibility of the fundraising for the school operations as part of their CSR initiative. http://thechoicetochange.org SEPTEMBER 2015 | Automation INSIGHT! | 61
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ASSIGN
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AUTO
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Photography
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Film and Video Production Digital Solutions and Web Development
We Give Your Creativity
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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. 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
Automation INSIGHT!
CIRCULATION Qatar
5000 COPIES
Oman
Kuwait
The 5,000 copies are split accordingly. It goes specifically to end users, EPCs & vendors working in the Automation, Process, Instrumentation & Controls industries. It is a very targeted audience which no other publication in the region provides:
Bahrain Saudi Arabia UAE
Saudi Arabia UAE Bahrain Kuwait Qatar Oman
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 • Digital Oil Fields • Technology and Implementation • Installation, Operation and Maintenance Issues • Multi-Phase and Wet Gas Flow Meters • Obsolescence & Lifecycle Management of Control & Safety Systems • Alarm Management & Rationalization • Turbo-Machinery Control and Load Sharing Systems • Ex Standards • Project Feature • Project Listings
48% 32% 7% 5% 4% 4%
2,400 copies 1,600 copies 350 copies 250 copies 200 copies 200 copies
Automation INSIGHT!
2015 EDITORIAL CALENDAR
Volume 3: Issue 1
Volume 3: Issue 2
Volume 3: Issue 3
Sector Feature: Offshore
Sector Feature: Drilling & Production / Power &
Sector Feature: Refining, Petrochemical
Deadline: 15th January 2015
Deadline: 20th February 2015
Deadline: 5th May 2015
Water, Pipeline Technical Feature: Tank Storage
Technical Feature: Digital Oilfield / Technology &
Technical Feature: Control System Cyber Security /
Implementation / Asset Performance & Productivity
Wireless & Industrial Communication / Advanced
Enhancement
Applications / Custody Measurement
Country Feature: Qatar
Country Feature: Bahrain / Oman
Country Feature: UAE
Additional Event Distribution:
Additional Event Distribution:
Additional Event Distribution:
• PMI AGC Biannual Conference - Bahrain
• Middle East Electricity – UAE
• ADNOC DMS Automation Event – UAE
• Offshore Middle East – Qatar,
• MEOS – Bahrain
• Gulf Industry Fair – Bahrain
• RPEC – Oman
• Kuwait HSE – Kuwait,
• Wetex - UAE
• Middle East Turbo-machinery – Qatar • Tank World Expo - UAE
Volume 3: Issue 4
Volume 3: Issue 5
Technical Feature: Process Engineering / Process Analyzers / Installation,
Technical Feature: Alarm Management & Rationalization / Functional Safety &
Maintenance & Operational Issues / Multi-Phase & Wet Flow Gas Meters/
SIS / Industrial Automation & Control
Deadline: 5th September 2015 Sector Feature: Gas
Deadline: 5th November 2015 Sector Feature: Oil
Obsolescence & Lifecycle Management Of Control & Safety Systems
Country Feature: Saudi Arabia / Kuwait
Country Feature: UAE
Additional Event Distribution:
Additional Event Distribution:
• MEPEC – Bahrain
• ADIPEC – UAE
• Gastech – Singapore
• IPTC - Qatar
• KOGS - Kuwait
Full Page $4,000
Trim Size: 200 x 279mm Bleed Size: 206 x 285mm
Double Page Spread
ADVERTISING RATES
$5,000
Trim Size: 400 x 279mm Bleed Size: 406 x 285mm
PREMIUM POSITIONS
*And each additional page $1000 per page
Outside Back Cover
$7,500
Inside Front Cover
$6,000
Inside Back Cover
$6,000
All artwork to be at least 300dpi in Jpeg, PDF, EPS or Tiff format CMYK with bleed and sent directly to the production designer: email: jgelangco@dmsglobal.net
Half Page Horizontal Trim Size: 190mm x 135mm Bleed Size: not required $2,000
Half Page Vertical Trim Size: 95mm x 270mm Bleed Size: not required $2,000
Quarter Page Trim Size:95mm x 135mm Bleed Size: not required $1,000
With approximately 5,000 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.
To advertise or place an article, please contact us.
Tel: +973 1740 5590 Email: automation@dmsglobal.net
www.dmspublishing.net