SuccessStory InFusion PetroRabigh 03-10

8/10/2019 SuccessStory InFusion PetroRabigh 03-10

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Invensys OperationsManagement solutiohave demonstratedconsistent ROI payiout in as little as sixmonths, but definitelwithin 12 months.

Yadukulatilakam Ramaswamy

Senior DirectorInvensys Operations Manageme

Invensys Operations Management Solution SupportsPetro Rabigh

Goals Implement a Plant Information Management

(PIM) System fully integrated with SAP and otherapplications in advance of commissioning theexpansion of the original refinery.

Improve performance management by tightlyintegrating control systems with production andcorporate business functions.

Maintain system safety, plus optimize productionquantity and quality at a competitive cost.

Challenges The integration needed to seamlessly unite a

wide variety of business functions. Business and Operations Management systems

had to be synchronized to have a single versionof truth across the enterprise.

Changing market dynamics required a robustplatform to be flexible and agile to react quickly.

The project required a global team with multi-disciplinary skills to ensure successful delivery.

Solutions and Products InFusion Enterprise Control System with a

number of Invensys and Third Party solutions.

Results The Invensys solution covers the entire refine

and petrochemical complex comprising23 plants.

Best-in-class applications from several vendoincluding Invensys and SAP, were integratedthrough the InFusion Integration Infrastructur

Setup, configuration and testing of theapplications and KPIs were smooth due to theflexibility of the InFusion environment.

The enterprise receives continuous, accurateperformance feedback, which is drivingconsistent execution of business processes.

INDUSTRY: HYDROCARBON PROCESSING

Petro Rabighwww.petro-rabigh.com


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Rabigh, Saudi Arabia Since 2005, this portcity on the Red Sea has been home to a majorrefinery. The PetroRabigh complex produces fuelsand petrochemicals for the domestic market andexporting to Europe and Asia.

Petro Rabigh is one of the largest fully integratedoil refinery and petrochemical production facilities

in the region and it is the largest integratedrefinery in the World built in a single time. It iscomprised of 23 plants that produce 18.4 milliontons per annum (mpta) of petroleum-basedproducts and 2.4 mpta of ethylene and propylene-based derivatives.

When management decided to expand thefacilities, they set a goal of commissioning theplants with integrated operations managementand business systems by 2009.

Improving Performance Management

The objective of the PIM System Project was tointegrate the disparate functional systems in thecomplex to improve management of the plantoperations. In its original iteration, productionand corporate business functions were separated,which did not give executives the overall visibilityand access to data that would help them makeinformed decisions about production levels,

supply, demand, use of resources andpersonnel allocation.

To meet this goal and respond to the pressures ofa changing global economy, Petro Rabigh requireda system that would unite planning, scheduling,operations management, production accountingand other tasks. Ideally the new platform wouldenable various plants to share information andcommunicate. The plant level systems had to beintegrated with the business system, namely, SAP.

Choosing the Right Solution, Assembling aTalented Team

The InFusion Enterprise Control System (ECS)was a natural fit. Designed on open, industry-standard technologies, the solution would be ableto synchronize information from multiple systemsand applications.

Plus it was proven to unite them within a singleenvironment that would provide consolidated andcontextualized data in real time, versatile objecttemplates for repeatability, and other capabilitiesthat provide ease of operation and reduced totalcost of ownership.

Invensys Operations Management solutions

have demonstrated consistent ROI paying outin as little as six months, but definitely within 12months, said Yadukulatilakam Ramaswamy, SeniorDirector with Invensys Operations Management.

And when it came to the people who woulddeliver the solution, PetroRabigh and Invensys metthe challenges together. A diverse, global teamwas assembled, including application engineers,process engineers and project development andmanagement experts from Invensys Middle East,Europe, India and North America.

The Invensys Netherlands group was the hubfor the senior technical team and also hostedthe Factory Acceptance Test for the solution.And finally, the development team worked fromthe Invensys offices in Dubai, UAE as the systemmigrated towards commissioning.

To maximize efficiency and minimize travel costs,much of the work was accomplished via remotenetwork connections.


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The multi-disciplined environment helped ourengineers contribute from across the globe. Thisincreased efficiency and minimized cost while thecentralized database ensures that maintenanceeffort and cost will be reduced, said Eva Hachem,Lead Engineer with InvensysOperations Management.

Flexibility and Functionality

The Invensys InFusion platform integratescomponents to form the foundation of the PIMSystem:

Laboratory Information Management System(LIMS) Manages the laboratory and organizesmultiple processes into one databasewhere analytical data is entered, stored andmanaged. Lab results are supplied to theother PIM system applications.

Operators Logbook This applicationintegrates with InFusion to collect real-timedata, manage operations and personnelscheduling, plus visualize production orders,handle KPIs, sample results, downtime andmass balance error events.

Mass and Energy Balance This applicationprovides hourly and daily reporting ofreconciled production data. It supplies datathrough InFusion for KPI calculations and

interface with SAP. KPI Key Performance Indicators are

computed in InFusion environment.Calculated results are stored and madeavailable enterprise-wide.

Downtime Monitoring Stops, starts andruntime data are collected and stored byInFusion and reported to the Logbook.

Oil Movement and Management Tankfarmmanagement and oil movement are handledby this part of the system, including inventory,

order management, optimization of oil blends,batch tracking, and other functions.

Alarm Management The critical data fromthe monitoring of events and alarms can beviewed from the unified PIM viewer interface.

Planning and Scheduling Long, mediumand short-term plans are generated usingLP models and broken down into dailyschedules, production targets and operatinginstructions. Shift and resource requirementsthat will maximize output are generated andproduction and performance are measured.

During design and testing, the flexibility of theInFusion system enabled concurrent design effortswhile ensuring that project milestones were metand proper testing was performed.

By harnessing these capabilities under a single,integrated environment, the Invensys solutionprovides Petro Rabigh significant improvement inthe management of the complex and substantialfinancial savings into the future, said Ramaswamy.

Efficient to Build

System engineers reviewed the designspecifications and created spreadsheets todevelop layouts and KPI templates. Tags wereused to define standard incidences for eachtemplate, which were simply imported into theInFusion environment.

Much of this work was drag-and-drop, sinceInFusion allowed engineers to inherit tag instances

and replicate redundant attributes. The attributeswere pulled into InFusion using .csv files, savingdata entry time and errors.

Moreover, User Defined Attributes (UDA) extendedthe platforms functionality by enabling theaddition and customization of the parameters ofthe KPI configurations. Extensions and advancedscripting capabilities aided in the design anddevelopment of the system.

Easy to Use

In the new solution, operators view and controlall of the applications within the PIM systemvia a web-based, unified user interface. Theenvironment enables planning for maintenanceand updates.


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Plus engineers and management can generatetrends and reports which can be displayed inreal time or stored in familiar applications likeMicrosoft Word or Excel documents, AdobePDF, HTML and others.

Updates are straightforward. InFusions object-oriented framework means that the system can

be easily modified with just a few commands.Changes can be made onsite orremotely deployed.

Invensys is no newcomer to global sized projects,yet bringing the best people and technologiestogether was quite unique. The decision wasmade to center the team in the Invensys AdvancedApplication Services Division, located in theNetherlands where the applications developers,programmers, and managers could collaborateand communicate. Location and collaborationwere key to project success., said Patrick Murray,Principal Engineering Consultant with InvensysOperations Management.

Accuracy of data sharing is also improved.Formerly, passing information between differentareas of the complex such as transferringstatistics from PLC/SCADA to production control(ERP) was manual, redundant and fraught withopportunities for error. Now, the integratedsystems share the correct data securely, which

enables management to gain useful insights.

The InFusion integration capability is humongous.Theres no single application we could not plug in,not a single requirement we missed. It wasthrilling seeing it grow to what it is today,remarked Hachem.

Integrating People and Technologyfor Success

The Invensys leaders for this assignmentacknowledge an extensive list of relationshipsand resources that made the PetroRabigh effortsuch an achievement: a visionary and supportivecustomer, collaborative partners and

dedicated employees.

Pulling together their energies around aninnovative solution has resulted in a best-in-classresult. This complex integration is fulfilling thedesire to bring advanced applications together tomeet and exceed customer demands.

Invensys, the Invensys logo, ArchestrA, Avantis, Eurotherm, Foxboro, IMServ, InFusion, SimSci-Esscor, Triconex, and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All otherbrands and product names may be the trademarks or service marks of their representative owners.

2010 Invensys Systems, Inc. All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form or by any means, electronic or mechanical, includingphotocopying, recording, broadcasting, or by any information storage and retrieval system, without permission in writing f rom Invensys Systems, Inc.

Invensys Operations Management 5601 Granite Parkway III, #1000, Plano, TX 75024 Tel: (469) 365-6400 Fax: (469) 365-6401 iom.invensys.com

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SuccessStory InFusion PetroRabigh 03-10