ApplicationSolution

Summary

This paper explains how

the implementation

of a Plant Information

Management

(PIM) System was

integrated with SAP in

one of Invensys’ major

customer sites in

the Middle East, Petro

Rabigh.

Business Value

• Remove barriers

between corporate

business functions,

engineering and

production

• Optimize production

quantity and quality

• 6 to 12 Month Payback

for Investment

INTRODUCTIONThe refining of crude oil to produce fuels and petrochemicals encompasses a variety of process technologies. Automation systems used to manage these systems work to operate in a safe environment and optimize production quantities and qualities, at a competitive cost. These disparate systems strive to reach a common goal by serving managers, engineers and operators but are extremely complex as each subsystem is best-in-class focusing on a narrow aspect of the business. Integrating them into an enterprise-wide solution is often difficult. The InFusion™ Integration Infrastructure proved to be an ideal platform for the integration, orchestration, and reporting/visualization framework for this overall solution.

With such a powerful platform the barrier between the business side and the engineering and production side of the plant is completely removed. SAP, which is used to manage business data (such as production orders, schedule, and material costs), can now receive quality production data from the Operations Management layer through one seamless interface with the InFusion™ Enterprise Control System. Such high quality, reconciled production information and other operating parameters can also be used for performance management.

This paper explains how the implementation of a Plant Information Management (PIM) System was integrated with SAP in one of Invensys’ major customer sites in the Middle East. Winning this ground-breaking project required a paradigm shift in changing the integration philosophy from using Real-Time Database (RTDB) as the integration platform to using a component object-based, service-oriented integration technology offered in the InFusion Enterprise Control System. The customer understood the benefits of using such an expandable and scalable architecture, which also allows user modifiable objects to be developed remotely and then integrated into production environment after testing. The PIM System was implemented using best-in-class applications from several vendors including Invensys integrated through the InFusion Enterprise Control System.

Plant Information Management SystemOrchestrating Complex Systems to Work as One

Typically, the return on investment (ROI) from integrated Operations Management Systems is 6 to 12 months, but often the real savings is realized for years after the go-live date through the ease of implementing changes and adding additional systems. Want to add a backup pump for waste water disposal? Not a problem, just copy an existing template with most of the parameters installed.

is nowInvensys

SCOPERabigh Refining and Petrochemical Company (Petro Rabigh), Saudi Arabia, a Joint Venture between Saudi Aramco and Sumitomo Chemicals of Japan, took on the expansion of the original Topping Refinery into a conversion refinery and a huge Petrochemical Complex to produce fuels, monomers and polymers at a single facility with a vision to establish itself as a world leader in the industry. With the commissioning date set for early 2009, they required the PIM System integrated with SAP. The scope of the project was to develop the business processes supported by a suite of technologies to perform planning, scheduling, operations management, production accounting and performance management functions in an integrated manner. The PIM System seamlessly integrates with SAP to perform the higher level business functions with reliable information from the refining and petrochemical complex.

This paper briefly discusses the site-wide expansion and new development, focusing on the aspects of the enterprise control system and demonstrating the power of the InFusion Enterprise Control System as the integration infrastructure. The ease of setup, configuration, and testing of the applications and KPI’s in InFusion Enterprise Control System environment are reviewed as described in the functionality of the InFusion Foundation Edition software.

PROJECT RATIONALE AND EXPECTED BENEFITSDiverse systems working on their own (islands of automation)The Petro Rabigh refinery was similar to other large scale processing plants with cell technology working well to complete its function but unable to communicate well with other areas in the plant, much less business systems. Obtaining discrete or analog output to trigger an alarm or perform a function within that cell (such as PLC/SCADA) has been the domain of the controls engineer. Sharing that data with production control (ERP) is still somewhat tedious and the redundant task of manually transferring data is fraught with opportunities to make mistakes.

The Petro Rabigh complex is similar to other large scale processing plants that require robust integration of information to be communicated between several entities with the organization and business systems.

Time is critical in complex projects because the systems often become obsolete before implementation is complete. This is where an open, component object-based system allows the development continuum to proceed as the InFusion model based on ArchestrA® Technology does not need to be recreated each time a change takes place. Just a few years ago, the pressure gauge required that analog signal conditioning be done downstream in a feedback loop, and be packaged entirely inside the device. This is where the flexibility and power of the ArchestrA Technology’s open structure pays off. Unanticipated changes at the sub-system level are easily handled with only a few mouse clicks.

The inseparable bond between time and money were key drivers in the customer’s selecting the InFusion Enterprise Control System as the platform for enterprise-wide solutions. The global economy at the start of this project (October 2007) was demanding products, yet keeping cost in line with a lean budget was key. Fast-forward to the market collapse a year later, product demand plummeted, necessitating agility to changing marketing environment. Now the decision to pick an infrastructure to support this requirement with modular flexibility and providing reliable information to the business system, makes the choice look even more brilliant and speaks volumes of customer’s vision to go for such a solution!

Figure 1. ArchestrA Model

THE REFINING AND PETROCHEMICAL COMPLEXNew build for capacityThe Rabigh facility is an upgrade of an existing 400 MBD topping refinery and construction of a new petrochemical complex. A range of refined products (130 million bbl per year) will be produced including, gasoline, diesel, fuel oil, naphtha, jet fuel, and kerosene. This showpiece upgrade includes the high olefins fluid catalytic cracker complex integrated with an upscale ethane based cracker. When this facility comes on line, it will be able to produce 2.4 million ton/year of polyolefin’s petrochemical derivatives.

Petro Rabigh’s key requirement was to integrate their control systems tightly with production and corporate business functions, thereby enhancing planning, scheduling, directing and managing activities across the Rabigh Refinery and Petrochemical Complex. The specifications called for a Real-Time Database (RTDB) based integrated solution while Invensys convinced them of the disadvantages of such an approach and proposed a Component Object-Based, Service-Oriented integration infrastructure which became the rationale behind the Customer’s selection of Invensys solution.

We based our solution on Invensys’ flagship Enterprise Control System product, InFusion that integrates tightly with the specified Exaquantum real-time database and historian, while providing the integration, orchestration and reporting/visualization framework for the overall solution. The InFusion-based solution at Petro Rabigh enables consistent, accurate performance feedback – a key driver to consistent execution of the business. InFusion’s open, structured but user-modifiable object oriented architecture precisely fosters this: ongoing changes can be centrally effected and remotely deployed to keep the system always up to date, with the expertise of internal resources encapsulated and automated within the system.

In our experience, Invensys solutions have demonstrated consistent ROI – sometimes paying for themselves in as little as 6 months, but with 12 months normally achieved. By harnessing the capabilities of our proven industry solutions under a single, integrated environment, Invensys’ solution provides Petro Rabigh significant improvement in the management of its Rabigh Complex and substantial financial savings into the future.

Yadukulatilakam Ramaswamy, Invensys

Figure 2. An Overview of Petro Rabigh Facility

GeographyLately, you hear the term ‘Global’ used quite often; With a customer located in Rabigh, Saudi Arabia, the development team located in the Netherlands, with concurrent efforts taking place in the US, Hyderabad- India, Dubai, Tunisia, and Montreal, this project took on a legitimate ‘global’ claim.

Invensys is no stranger to global sized projects, yet bringing the best people and technologies together was quite unique. The decision was made to center the team in the Invensys Advanced Application Services Division, located in the Netherlands where the applications developers, programmers, and managers could collaborate and communicate. Quick and easy solutions were reached with input from the site in Saudi Arabia. Additionally, east and west locations could be coordinated in a balanced time zone, using web meetings.

SOLUTION HIGHLIGHTSThe breadth of a project of this magnitude took a great deal of coordination between different team members. Everyone working on different applications to the same set of development standards, specifications and drawings required close coordination and good communication.

The list below illustrates the list of applications constituting the integrated solution coming online at rollout of the Plant Information Management (PIM) System:

1. Data Acquisition and Historian2. Alarm and Event Monitoring3. Plant Data Modeling4. Mass and Energy Balances including data reconciliation5. Plant-wide material balance and production accounting6. Tank Information System (TIS)7. Order Movement Management (OMM)

8. Laboratory Information Management System (LIMS)9. Operations Logbook10. Emissions monitoring11. Downtime monitoring12. Data Reconciliation13. KPI collection and calculation14. Integration with SAP

While all sub-systems were included in the setup of the integrated system, the last four items (11 through 14) are discussed in further detail below to confine the length of this discussion.

InFusion Enterprise Control System, the right tool for the jobToday, the need for platform independent solutions can’t be overemphasized. Alliances have been formed and the lines drawn but these relationships last only as long as the project they are serving and customer needs are met. These dynamics are even more pronounced in the commodity market such as petroleum products. The choice came down to the static uniformity of using one vendor’s suite or the flexibility by picking the best-in-class solutions for each application from multiple vendors. Invensys’ InFusion component object-based and service-oriented framework has proved to be an ideal platform that had the flexibility of easily modified objects that showed remarkable promise for adapting to the dynamic environment within the market. Both solutions work to integrate the production and business operations sides of the business, but the difference is in how this was achieved. The InFusion Enterprise Control System model uses a bridge layer from operations in the structure that lends endless capabilities for modular expansion and works with real-time data requirements and historized data, while meeting the requirements for conformance to standards (such as ISA-95). OMM, TIS, SAP, and LIMS now have the flexibility to bolt on additional applications.

System Description1

Illustrated on the next page are the functional components of the PIM System. They communicate with each other and relate to the external systems IWSPP (Independent Water, Steam and Power Provider), PCS (Pro-cess Control Systems) and SAP. These interfaces are defined in the design specification’s internal interfaces._____________________________________________1 Source: PIM System project FDS, 8SA-1-PJ-001, Rev 1.1, 26-Nov-2007

Petro Rabigh’s first priority was the collection of production progress data needed to fulfill the SAP data requirements. The result shows that the data in SAP is much more reliable than manually entered. To achieve this, the production tracking module collects data from various sources (such as DCS, TIS, and OMM) and, using an object oriented plant model, transforms this into production tracking data, like materials consumed and produced per production order and a history of tank levels. The mass balancing applications (MBM and GERA) then serve to enhance the quality of the data by validating its consistency and applying, statistically plausible, corrections to the raw data. Any inconsistencies, which cannot be explained by the known inaccuracy of the various meters and sensors, are signaled and corrected manually by the production accountant. The result isa set of formally approved and consistent data, which is sent to the SAP.

Furthermore, the PIM system supports the daily operation in reporting various production events (such as start/end of importing/shipping, and product tank filled) which, among others, automatically instruct the lab to take and analyze material samples.

In the near future PIM will also serve as a source of data for an advanced planning and scheduling system, which will convert the rough monthly planning in SAP to a daily production planning. The results of this planning will be sent to PIM to be shown as operator instructions in the operator logbook and as a basis for the creation of planned orders in the OMM system.

Udo Zwart, Senior MES Consultant

Figure 3. System Architecture

PIM SYSTEM – FUNCTIONAL OVERVIEWThe InFusion Enterprise Control System integration layer is the core to the PIM System and access to all PIM applications listed above, data storage and retrieval are available from this domain. The data definition is done in the InFusion Engineering Environment (IEE). The real-time data from the Process Control Systems and the Utilities plants, IWSPP are received in the PIM system through an OPC interface and stored in the Data Acquisition and Historian System (DAHS_ Exaquantum). The legacy data from an old PI system in the Refinery was migrated to the DAHS, with the DAHS as the primary storage of process data. Only the data is required by applications that connect to InFusion; objects are copied from the InFusion Enterprise Control System Environment. The particular application that requires DAHS data, accesses the specific InFusion object, representing the data. Real-time data required by the applications is made available using InFusion Data Access Servers (DAS). The OPC and required historical data are retrieved using an InFusion proxy to retrieve the data. Both of these methods are transparent to the users of the data. The results are created by an application and stored in the InFusion Historian.

The functionality of the supporting applications is tabulated below. Each application is fully autonomous, has the interconnectivity capability without the need of OPC setup, and has the uniformity of design from the ISA-95 protocol. These systems where configured independently and then incorporated in the InFusion integration environment. This flexibility of InFusion enabled concurrent design efforts while insuring that all systems met the customer’s requirements in design and testing.

Table 1. Application Components

LIMS Logbook Mass Energy Balance KPI

LIMS organizes multiple lab processes into one cohesive database. Analytical data is entered, stored, and managed in LIMS. SAP QM IDI serves as the interface. Lab results that are related to a plant sample locations are made available to the other PIM System applications with the help of an InFusion proxy.

The Logbook application is integrated with the InFusion Enterprise Control System for the purpose of visual-izing production orders, handling KPI excursions, sample failures, off-spec sample results, downtime and mass balance error events. The operator may include data from the InFusion environment by a selection feature in the Logbook to collect real-time data from tags in the InFusion plant model (including lab sample data). It also acts as an electronic medium for managing operations (operation instructions, shift logs, shift handover etc.).

The complex wide mass and energy balance and data reconciliation ap-plication is run every day to provide reconciled production data. The input data consist of aggregated mass flow data from the InFusion integration layer and the output data is available for the KPI calculations and the SAP interfacing. The unit based mass and energy balance application is run every hour to detect measurement and model errors and to provide input data for the complex wide mass balance and data reconciliation.

Key Performance Indicators (KPIs or PI’s) are implemented in the InFusion environment. The required input data is retrieved from the InFusion environment and the calculated results are stored in the InFusion environment. These values are available to the SAP system.

Downtime Monitoring Production Movement & Mgmt. Alarm Management Planning & Scheduling

Down Time monitoring or ‘Run Time’ monitoring is implemented in the InFu-sion environment. For all plants and units and critical equipment the ‘Running’ or ‘Stopped’ status is de-termined from the process. The number of starts and run time is stored in the InFusion environment and each time an object changes states to the ‘Stopped’ status a downtime event is reported to the Logbook.

Oil movement within the refinery and monomer complex is aided by the TIS/ OMM functionality and control systems. Tank inventory, order management, blend optimization, movement automation, analyzer management, batch tracking and other functionality can be controlled as a key feature of the PIM System suite of process control.

The alarm and event monitoring ap-plication has been designed to have a direct connection to the PCS OPC servers as the DAHS (Exaquantum) does not support an OPC AE server, nor does InFusion have an OPC AE client. There is no integration with the InFusion environment apart from the launch pad in the PIM System user interface. The alarm and event monitoring application is capable of presenting the alarms and events combined with process trend data. The data are retrieved from DAHS using OPC HDA on demand.

Long range planning and me-dium/ short term planning are performed using LPs and the approved plan is broken down into daily production requirements in the schedule. Targets are set for production based on shift require-ments and resource availability. Actual yields are balanced against production requirements to maxi-mize output. The schedule is the main focal point for production and performance measurement (against the plan).

The PIM system has a unified user interface which provides access to all PIM System applications. A web environment is used to display mimics and trends in which a combination of overview (InFusion) and detailed mimics (Exaquantum) and trends may be viewed and analyzed. A series of predefined reports may be created using the reporting interface. The data are collected using ‘SQL-stored procedures and views’ and formatted by InFusion Reporting (based on the Microsoft SQL Server Reporting Services infrastructure). The final result can be stored as various types of files (PDF, Word, Excel, HTML,…) and displayed in the web environment. The stored files may be accessed later on demand. Stored MS Word files can be edited or combined into new reports by the user.

Plant Model Design ConventionsThe basis of the PIM System design is the ISA-95 terminology and plant model concept; using this model the site can be regarded as built from areas and production units, process cells, and units. ‘Units’ in the ISA-95 structure can be part of only one plant. However, the Petro Rabigh structure may have a unit defined in several Plants. For example, CT_123 (cooling towers unit) is part of the following plants: DTL, ECR, HOF, PEG, and UTL. In the InFusion plant model the CT_123 unit has been separated into sub-units, each belonging uniquely to one plant. The unit name of the sub-unit is created from the unit name by adding an underscore (such as CT_123) and mnemonics to specifically identify the plant. In the InFusion plant model, the sub-unit is used and accessed just as any plant unit.

ISA-95 is the standard for the integration of enterprise and control systems. ISA-95 consists of models and terminology used to determine which information must be exchanged between systems for sales, finance, logistics, and systems for production, maintenance, and quality. This information is structured in the UML models and provides the basis for development of standard interfaces between Operations Management and ERP systems.

INFUSION – EASY TO USE, FLEXIBLE PLATFORMThe ease of use and flexibility of the InFusion Enterprise Control System can best be described by understanding performance as illustrated in the following example:

$PI Performance IndicatorsThe inherent flexibility to adapt to changes in the system will provide future benefits to the system expansion and scaling. The PIM System initial build required a systematic approach to extracting information from the process flow diagrams, specifications, and building the tag structure to allow information to flow from the subsystems and field devices into the DCS and Historian. The performance monitoring system is the feature diagnostic and analytical area of the system.

Petro Rabigh truncated the industry standard ‘KPI’ to ‘PI’ as they saw no significance in monitoring an unimportant performance indicator. The areas of focus for traditional disciplines (such as quality, cost, schedule, and safety) can be distinguished at the user level through reporting and user screens.

System Engineers made this build very simple with spreadsheets that were used to layout the design intent from design specifications then search the Exaquantum historian to find the input tags to generate the parameters necessary for the InFusion Enterprise Control System to create an output (such as trigger an alarm for H2 consumption – too high, as shown in Table 2). The spreadsheets where then used to generate performance indicator templates. The InFusion Enterprise Control System allows the engineer to build, assemble, and design requirements and specifications into standard instances (such as a template in the InFusion Environment).

Once the template was ready, all configuration information (such as $PI name, the unit it belongs to, Input Tags, and Alarm Limits) was populated into a spreadsheet. The text format or *.csv (comma delimited) files were imported into the InFusion Platform resulting in ready to run $PI, called instances in the InFusion Enterprise Control System.

The $PI instances select their input values from Exaquantum Tags. These inputs are usually aggregated values (average and sum) over 24-hours. When the aggregation is unavailable from the DCS, it is handled by the InFusion System at the Historian level. Event Tags and Stored Procedures were developed to submit this information to the running PI.

By starting with an initial $PI template, the following configuration information was required to provide full functionality:

• Field Attributes • UDA (User Defined Attributes) • Scripts• Object Information • Extensions

A sample $PI Design Spreadsheet is shown in Table 2. This tool is a simple spreadsheet that captures the design intent, H2 Consumption in this case, with a logical flow of the formula to be used as the key performance indicator, followed by the inputs. The engineering units are then labeled below along with ancillary information such as functional notes that allow the engineer to configure the point’s value in the terms that the end user will want to see as output.

Table 2. Engineering Design Spreadsheet

The tags (instances in InFusion lexicon) were populated into the shell structure of the InFusion site-specific environment of the Galaxy, as shown in Figure 5.Most of the work was to drag-and-drop as many of the redundant attributes. The InFusion Enterprise Control System allows the designer to replicate these redundant attributes by inheriting tag instances (such as parent to child relationship). The attributes, shown as instances in Figure 5, were pulled into the InFusion model using a *.csv file, saving data entry time and errors.

Figure 4. Derivation (tree) and Field Attributes

UDA – User Defined AttributesOnce the instances are setup, User Defined Attributes (UDAs) aid the full functionality of InFusion. The UDA allows the designer to satisfy process variables for the cost and quality requirements. Design and testing can be done concurrently by deploying whole sections of the Galaxy1 without interruption to production.

As the name implies, the UDA allows adding and customizing parameters through the $PI configuration. The $PI acquires data from disparate sources and routes the data throughout the $PI system’s infrastructure. These parameters can be a variety of types: Boolean, double, elapsed time, float, integer, string, and time. For each UDA, the engineer can specify an initial value and category. This is similar to securing access to the UDA (such as read/write), with each $PI instance having two sets of UDA’s – a set inherited from the Parent Template and a set of UDA defined for the specific $PI.

ExtensionsThe systems engineer can extend UDA functionality by: adding input and/or output extensions, locking the linked sources of outputs and alarms, historization, customizing the engineering units of measure per UDA, and changing other variables for fully customized control.

Additional functionality can be found in the ‘Extensions’ tab (not illustrated here) that allows the engineer to drive the inheritance relationships of inputs and outputs, customize the engineering units of measure, lock the linked sources of outputs and alarms, and change other variables for fully customized control.

ScriptingFinally, scripting capability enables the engineer to develop calculated functionality right into the development interface (see figure 6). Simple Boolean scripts, logical expressions or complex arrays can be used to drive the output and linked tags to yield desired results.

Scripts developed for Petro Rabigh KPI’s, made sure that engineering units for the DCS value falls in line with the mandatory formula requirements. In some cases, the conversion multiplier was used to factor the values from the DCS and in InFusion (such as unit of measure)._____________________________________________1 Galaxy is a term InFusion uses to define the entire application. It encompasses the complete ArchestrA system consisting of a single logical name space (defined by the Galaxy Database) and a collection of Platforms.

Figure 5. User Defined Attributes

The script executes the formula and then handles all possible exceptions such as a mathematical logic error that is encountered from a division by zero. Additional parameters handled by scripting are based on certain conditions (such as exceeding upper and lower limits of a parameter). The script sends a message to the Operator LogBook applications for notification and alarming.

These 6 sheets (Field Attributes, Object Information, Scripts, UDA- User Defined Attributes, and Extensions omitted for brevity) tabulate the layers that comprise the building blocks of the designer’s workspace. This much flexibility and powerful design capability in so compact a work space make for a blend of elegance and power in a simple design tool.

But enough about the design gadget! Who were the people that pulled the design requirements together and carried out the mission of designing and building the system? The people side of the project was at least as interesting as the technical aspects outline above.

Figure 6. Scripts Tab

KEY TO MISSION SUCCESS – PEOPLE IN THE MIXWorking on an international project can be an experience of a lifetime. The rewards are many but the challenges can be taxing.

Assuming you can surmount the language barriers and navigate through cultural nuances, you still must complete tasks and deadlines. Projects are inherently collections of divergent people with different needs and perceptions. Luckily, the ‘work of it’ (things to be completed) can draw people together toward a common end. Relationships get formed, people help each other, and the job gets done.

Having a workable location and supportive leadership will help keep things moving along and leave you with lasting work relationships while accomplishing more than you ever thought possible. The key is to open your mind to things that you do not know or understand and soak in the world. The project will keep you centered on the things that lead to success.

A project of this magnitude required an eclectic mix of people from across the globe. Once the project started, the Invensys project management team pulled together the resources required to get the job done.

The CustomerBeing a joint venture with Sumitomo and conceiving a business driven Plant Information Management System in the early phase of construction, Petro Rabigh has been unique in taking a bold and challenging initiative to implement an integrated enterprise-wide system that is fully operational as the plants come on stream. They were undaunted by the challenges posed by the lack of actual data to validate the solution while the complex was still under construction and were quite appreciative of the difficulties in commissioning the system under such circumstances, proving themselves to be a wise and well disciplined customer. The Project Management Team demanded excellence and set high expectations at every stage of the project. They exhibited technical competence and the spirit of cooperation throughout the project life cycle that proved invaluable in commissioning the solution in a challenging environment.

InvensysApplication engineers from the Invensys Middle East, Europe, India, and North American offices accomplished the construction and development of the system. The project was managed with the help from local professionals and managers with the mixture of people assigned to the project from various locations. The hosting location for this project was Invensys Systems N.V. (Baarn, The Netherlands) which specializes in designing, manufacturing, marketing and servicing instruments and systems for process management and control for the process industries. The senior technical lead insisted in bringing the resources to the Baarn hub to effectively launch and drive the project through completion. Baarn also served as a host site for the Factory Acceptance Testing (FAT). Invensys offices in Dubai, UAE became the next stop for the project team as development migrated toward commissioning.

The systems programming solutions provided the technical expertise for the mass of code underlying the simple symbols showing up on the customer’s screen, and process engineering expertise came from Invensys Development Centre, Pvt. in Hyderabad, India.

Project management and additional systems development had contributions from Invensys locations in Houston, Texas and Foxboro, Massachusetts, USA.

Much of the project was conducted remotely via network connections on this project to optimize team efficiency and minimize travel costs. Clearly, this was an international effort in true sense of the word.

From an engineering work effort perspective, InFusion altered the track from exigent to lenient. The multidisciplined environment helped our engineers contribute from across the globe. This increased efficiency and minimized cost while the centralized database ensures that maintenance effort and cost will be reduced.

With the large number of points and the continuously changing requirements as we proceeded, the different system features made it possible to accommo-date bulk changes in minimum time.

The InFusion Integration capability is humongous, there’s no single application we could not plug in, not a single requirement we missed. It was thrilling seeing this grow to what it is today.

Eva Hachem, Lead EngineerInvensys Middle East FZE

Invensys provides the most comprehensive portfo-lio of solutions—designed to measurably improve business performance and value in real time.

Enabled by our industry and production expertise, and accelerated by an open software platform and partner ecosystem, our flexible approach perfectly blends automation and information technologies, services and expertise into highly effective solutions. Solutions that solve problems and optimize the profitability of operations—from single plant devices, to multi-plant assets and locations, up through global supply chains and enterprise business systems.

Invensys offers the most holistic and cost effective way to optimize the business impact of your operation’s performance and overall profitability. We help improve the performance of your key resources (people, equipment, energy and materials) in real time—with dramatic, measurable results—using a collaborative and open approach.

Solution PartnersIn a project such as this, no man is an island and no company works in isolation, Invensys had help from other companies. This included competitors and consultants who worked in an open office environment where sharing information was of paramount importance. This was completed in deference to traditional sequestered development projects to quickly get the job done and with the collaboration of different technical experts. Even tasks of higher order of magnitude such as project management and technical specification definition was done with the help of non-Invensys partners.

The project reflected the multi-contractor effort at the plant construction level with much of the systems supplied by other companies. Great synergy was realized by adding people and companies of varying origin so a process flow diagram could be built into a working Operations Management System. No elaborate kudos was given here or needed - suffice it to say that their contributions were invaluable.

CONCLUSIONSPulling all this together is exactly what the InFusion Operations Management can do for very complex systems. The intersection of people and technology can make for a very difficult or palpable implementation; the degree of difficulty depends on bringing the right tools and hands together.

This article describes the combination of technical challenges and personal efforts of a well meshed team that put forth an enormous effort to deliver a best in class integration of the plethora of advanced systems that the customer demanded. Integration was the key; No other model fit the tall order for a profit driven market that required advanced applications that were made easy to deploy.

Construction Status as of July 20091:

The start-up of the Company’s New Facilities was originally scheduled for the 4th quarter of 2008. However, start-up was delayed to the 1st quarter of 2009 due to the delay in the completion of construction work that was generally caused by the tight labor market and the shortage in skilled labor. The construction activities were substantially completed by the end of December and the Project is in its start-up and commissioning phase. The ethane and butane gas pipelines, from Yanbu to Rabigh, that provide the Company with its feedstock, are now fully operational. All process plants have now been completed and handed over to the Company’s operation team. Construction work force, which peaked at nearly 40,000, is now below 2,000. Startup preparation activities are well under way and hydrocarbon has been introduced to several facilities as part of this exercise. At the time of writing this article all but the last polymer plants have been started up successfully.

_________________________1PR 2008, Annual Report to Board of Directors

GLOSSARY OF TERMS AND ABBREVIATIONS

Table 3. Terms and Abbreviations

Term as used in this document Meaning or Petro Rabigh equivalent wording

DAHS Data Acquisition And Historian System

DCS Distributed Control System

Enterprise Control System Enterprise Control System

ERP Enterprise Resource Planning

FDS Functional Design Specification

HDPE High Density Polyethylene

HDT HDS_VGO_HDT_HPU Plant

HOF HO_FCC_USGP plant

Galaxy The complete ArchestrA system consisting of a single logical name space

ISA-95 International Standard for the integration of enterprise and control systems

IWSPPCompany providing Combined Heat and Power services to all new plants at Rabigh (Independent Water, Steam and Power Provider)

KPI Key Performance Indicator

LIMS Laboratory Information Management System

LPG Liquid Petroleum Gas

MEG Mono Ethylene Glycol

MES Manufacturing Execution System

MS SQL Microsoft Structured Query Language database

ODBC Open Database Connectivity

OPC OLE (Object Linking and Embedding) for Process Control

PCS Process Control System

PEG Polyethylene glycol

PI OSISoft Plant Information

PIM System Plant Information Management System

QM IDI SAP Quality Management Inspection Data Interface

SAP System Analysis and Program Development

SAT Site Acceptance Test

SCECO Electric power company

UDA User defined attribute

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