PVC DCS UPGRADE PROJECT – BENCHMARK ACHIEVEMENT

1. PVC DCS UPGRADE PROJECT – BENCHMARK ACHIEVEMENT PRESENTED BY: Rashesh M Shah Project Leader 10-11th May 2004

2. About Petrokemya About PVC Plant About PVC Process Existing Systems Why to Upgrade? How to Upgrade? What to Upgrade? System Sizing System Configuration Major Challenges Strategies to meet Challenges Major Surprises Significant Achievements Acknowledgements

3. About Petrokemya • Petrokemya is wholly owned SABIC company producing Petrochemicals and Polymer Resins • Petrokemya facilities have Olefins (Olefins-1, 2 and 3), PVC/VCM, Polystyrene and Polyethylene Plants in addition to Utilities and Steam Generation • Petrokemya facilities have Installed capacity of about 5.15 Million Tons Petrochemicals per Year

4. About PVC Plants • PVC Plant operates Trains - A and B installed in 1986 with capacity of 100,000 MTY each • PVC Plant operates Trains - C installed in 1991 with capacity of 100,000 MTY • PVC Plant operates E-PVC installed in 1995 with capacity of 24,000 MTY • PVC Plant (Train-A and B) De-Bottlenecking was completed in 2003 to have additional 40% capacity

5. About PVC Process • PVC manufacturing is a BATCH process • Basic Raw Material is VCM which is produced by Ethylene and Chlorine • Petrokemya manufactures K67, K70 and K57 grades of S-PVC products • Petrokemya manufactures P701, P702 and P703 grades of E-PVC products • Application for K67 is General purpose (pipe, conduits, Furniture etc.) • Application for K70 Flexible purpose (mainly electrical cable) • Application for K57 Tough plastic (pipe fittings etc.) • Application for E-PVC is fine coating (Vinyl Flooring, Wall Tiles, Artificial Leather etc.)

6. Existing Systems • Foxboro SPEC200 based Analog Control System for Continuous Control • HIMA PLC for Discrete Control and Plant Shutdown • MODCOMP Classic II/75 Process computers for Batch Application and Data Collection • Foxboro INTERSPEC for Analog Signal Interface to MODCOMP Process Computers

7. Existing Systems • 09 Foxboro SPEC200 I/O Rack and Marshalling panels (Each 4.0 M Wide) • 16 HIMA PLC System and Marshalling Panels (Each 4.0 M wide) • 06 Dryer Room I/O and Control Panels • 16 MODCOMP Process computer Panels • 05 MODCOMP HIMA Interface Panels • 31 Operator Control Panels (Each 1.0 M Wide) • 06 Operator Control Desks

8. Why to Upgrade ? • Are the Systems Obsolete? YES… System was installed in 1986 Foxboro SPEC200 nest cards were obsolete MODCOMP Process computer was obsolete

9. Why to Upgrade ? • Are the Systems Obsolete? • Does System have expansion capacity? NO… Foxboro SPEC200 panel space were occupied HIMA PLC (for some units) capacity was fully utilized System did not have capacity to accommodate PVC De-Bottlenecking

10. Why to Upgrade ? • Are the Systems Obsolete? • Does System have expansion capacity? • Are we going to improve Operations? YES… Relocated existing Train-A/B Control room to create single common PVC Control room Removed Operations from separate Dreyer Satellite Control room Future plan for Single Operator for both Trains A and B

11. Why to Upgrade ? • Are the Systems Obsolete? • Does System have expansion capacity? • Are we going to improve Operations? • Are we going to produce more? YES… Application Software Optimization resulted in to smaller Batch time and higher production Reduced Downtime resulted in to increased production

12. Why to Upgrade ? • Are the Systems Obsolete? • Does System have expansion capacity? • Are we going to improve Operations? • Are we going to produce more? • Are we going to improve Safety and Reliability? YES… Critical Rotating Machines (Refrigeration Compressors) shutdown configured to ESD System Emergency Short Stop for Reactors configured to ESD System

13. How to Upgrade ? • Shall we involve Consultant or Engineering company? NO… Petrokemya decided to use in-house resources from Plant Engineering, PVC Operations and Control System Maintenance to form a TEAM to execute the Upgrade Project

14. How to Upgrade ? • Shall we involve Outside Consultant or Engineering Company? • Shall we involve PVC Process licensor? YES… Petrokemya decided to use PVC Process Licensor to develop Batch application and PVC De-Bottlenecking Integration

15. How to Upgrade ? • Shall we involve Outside Consultant or Engineering Company? • Shall we involve PVC Process licensor? • Shall we upgrade with the same manufacturer? NO… Petrokemya decided to go for Open Bidding Process to take advantage of latest technology and Vendor Support

16. How to Upgrade ? • Shall we involve Outside Consultant or Engineering Company? • Shall we involve PVC Process licensor? • Shall we upgrade with the same manufacturer? • Shall we execute Upgrades during plant ATA? YES… Petrokemya decided to execute Upgrades during plant ATA with PVC De-Bottlenecking Project

17. What to Upgrade ? • Conduct Feasibility Study Task Force was formed to conduct detailed Feasibility and Reliability study to identify all the System components that needs Upgrade

18. What to Upgrade ? • Conduct Feasibility Study • Conduct Safety and Risk Analysis Task Force was formed to conduct detailed Safety and Risk Analysis and identified ESD System requirements, Gas Detection, VCM Detection and Fire/Deluge System Upgrades

19. What to Upgrade ? • Conduct Feasibility Study • Conduct Safety and Risk Analysis • Shall we install Management Information System? YES… It was decided to install Process Management Information System for Operations Management, Data Gathering and Reporting

20. What to Upgrade ? • Conduct Feasibility Study • Conduct Safety and Risk Analysis • Shall we install Management Information System? • Shall we install Process Simulators? YES… It was decided to install Process Simulators for Operator Training, Process Modeling and Testing Process Modifications

21. System Sizing – DCS and ESD System

22. System Configuration

23. System Hardware • 06 FCS System Panels • 06 HIS (Closed Console Type) Operator Consoles • 06 Analog Interface Panels (1.8 to 2.4 M wide) • 15 Digital Interface Panels (1.8 to 3.6 M wide) • 01 Remote I/O Panel • 03 Auxiliary System Panels • 02 Power Supply Distribution Panels • 02 ESD System Panels • 04 ESD Marshalling Panels • 01 Bentley Nevada VMS Panels

24. System Hardware • 02 EXAOPC Servers • 02 Engineering Work Station (for DCS) • 01 Engineering Work Station (for ESD) • 01 SOE Work Station (for ESD) • 01 Supervisory Work Station • 01 PIMS Server • 10 PIMS Clients • 03 HIS Stations for Simulator System • 01 Engineering Work Station for Simulator System • 01 CAPE Simulator station

25. Major Challenges • Cut-over the entire system and integrate with PVC DBN project in just 14 days Management provided window of 14 days during ATA to make system up and running including new addition of PVC DBN Project It was very challenging considering the fact similar task would take not less than 21 days as per industry norms

26. Major Challenges • Cut-over the entire system and integrate with PVC DBN project in just 14 days • Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor PVC DBN Project, Batch Process Software Enhancement and Lack of Pseudo-codes for MODCOMP programs were driving force to involve Process Licensor, Oxy-Vinyl for Application Software Development

27. Major Challenges • Cut-over the entire system and integrate with PVC DBN project in just 14 days • Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor • Lack of Pseudo code or Logic Narratives for MODCOMP Batch programs and HIMA Logic For some reasons, Plant did not have these very vital documents to understand basis of application and subsequent approval of new application development

28. Major Challenges • Cut-over the entire system and integrate with PVC DBN project in just 14 days • Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor • Lack of Pseudo code or Logic Narratives for MODCOMP Batch programs and HIMA Logic • Lack of Ferrules/Tags on each and every wires Unbelievable but true… None of the wires in the plant, whether in field JB or Control room had Ferrules/Tags on them Since It was require to disconnect and re-connect more than 16,000 wires in control room it could create real chaos!!

29. Major Challenges • Cut-over the entire system and integrate with PVC DBN project in just 14 days • Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor • Lack of Pseudo code or Logic Narratives for MODCOMP Batch programs and HIMA Logic • Lack of Ferrules/Tags on each and every wires • As-Built condition of Plant Wiring Even though Plant documentation is updated regularly, about 18 years of Plant Operations and Hundreds of Plant Modifications calls for exact mapping of plant conditions We were not prepared to take even smallest of chance which could cost us a lot later

30. Major Challenges • Cut-over the entire system and integrate with PVC DBN project in just 14 days • Hardware execution by Yokogawa and Software execution by Oxy-Vinyl, Process Licensor • Lack of Pseudo code or Logic Narratives for MODCOMP Batch programs and HIMA Logic • Lack of Ferrules/Tags on each and every wires • As-Built condition of Plant Wiring • Integrate with existing Electronic HIMA MCC Modules VCM Upgrade gave us hard lesson when apparently simple interface turned out to be CRITICAL during start-up

31. Strategies to meet Challenges • TEAM Concept Petrokemya team consisted members from Engineering, Operations and Maintenance Project team consisted members Petrokemya, Yokogawa and Oxy-Vinyl

32. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN Considering two major modifications, PVC DBN and DCS Upgrades, engineers working on both the projects were common to have very close integration

33. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN • Reverse Engineer MODCOMP Batch Programs and HIMA Logic Reverse Engineering was performed to create Pseudo-code and Logic Narrative documents. These documents were thoroughly reviewed and approved to bench mark Batch application software development.

34. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN • Reverse Engineer MODCOMP Batch Programs and HIMA Logic • Pre-FAT Hardware at Early Stage of the project One (1) typical of each type of cabinets were fully assembled and wired to inspect layout, accessibility, labels, ferrules etc. to avoid any major changes after mass production.

35. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN • Reverse Engineer MODCOMP Batch Programs and HIMA Logic • Pre-FAT Hardware at Early Stage of the project • Comprehensive Operators/Technicians and Engineers Training Target Simulators and actual application software used for comprehensive Operator Training

36. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN • Reverse Engineer MODCOMP Batch Programs and HIMA Logic • Pre-FAT Hardware at Early Stage of the project • Comprehensive Operators/Technicians and Engineers Training • Joint Prototype Software Development Prototype software was developed and rules were defined for developing application to have consistency in look and execution

37. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN • Reverse Engineer MODCOMP Batch Programs and HIMA Logic • Pre-FAT Hardware at Early Stage of the project • Comprehensive Operators/Technicians and Engineers Training • Joint Prototype Software Development • Actual testing with existing Electronic HIMA MCC Modules Specific Isolators were required to be used to Interface with existing HIMA MCC modules as it can source only 3 mA current.

38. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN • Reverse Engineer MODCOMP Batch Programs and HIMA Logic • Pre-FAT Hardware at Early Stage of the project • Comprehensive Operators/Technicians and Engineers Training • Joint Prototype Software Development • Actual testing with existing Electronic HIMA MCC Modules • Wireman Interviews Skilled wireman were selected considering extremely tight schedule of re-termination during ATA.

39. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN • Reverse Engineer MODCOMP Batch Programs and HIMA Logic • Pre-FAT Hardware at Early Stage of the project • Comprehensive Operators/Technicians and Engineers Training • Joint Prototype Software Development • Actual testing with existing Electronic HIMA MCC Modules • Wireman Interviews • Loop Check from Junction Boxes Waiver to plant procedures was granted to check loops from JB instead of field element to gain on schedule without affecting functionality

40. Strategies to meet Challenges • TEAM Concept • Common resources for DCS Upgrade and PVC DBN • Reverse Engineer MODCOMP Batch Programs and HIMA Logic • Pre-FAT Hardware at Early Stage of the project • Comprehensive Operators/Technicians and Engineers Training • Joint Prototype Software Development • Actual testing with existing Electronic HIMA MCC Modules • Wireman Interviews • Loop Check from Junction Boxes • Integrated FAT at Jubail Staging Area Total System components, including third party subsystems, were assembled and Integrated FAT was carried out at Jubail staging area using target application software.

41. Major Surprises • UPS Power Capacity During Detailed design it was discovered that UPS power capacity, after upgrades do not maintain spare capacity margin requirements. We decided to upgrade existing UPS system

42. Major Surprises • UPS Power Capacity • Early Test Commissioning for PVC DBN Compressor System During Installation phase of the DBN project, Management decided to Test commission new refrigeration Compressor system. The team worked together to install ‘temporary’ set up to install DCS/ESD and Vibration monitoring system to achieve the objective.

43. Major Surprises • UPS Power Capacity • Early Test Commissioning for PVC DBN Compressor System • Impact due to Iraq Conflict Material Delivery and Shipments affected but fortunately overall schedule was unaffected Due to high alert, Personnel from Oxy-Vinyl did not participated in FAT

44. Major Surprises • UPS Power Capacity • Early Test Commissioning for PVC DBN Compressor System • Impact due to Iraq Conflict • Impact due to SARS in Far-East Yokogawa personnel from Singapore could not travel as scheduled However, Yokogawa managed to send some personnel from Philippines and fortunately overall schedule was unaffected

45. Major Surprises • UPS Power Capacity • Early Test Commissioning for PVC DBN Compressor System • Impact due to Iraq Conflict • Impact due to SARS in Far-East • Damage of the Existing System cable During Installation phase, One of the existing system cable was damaged and resulted in to loss of monitoring display of some unit of the plant under operation. Investigation revealed that cable was not ‘cut’ but some cores were shorted apparently during installation of the system cables. Incident compelled us to

46. Significant Achievements • Changeover of the system 5 days ahead of schedule System was installed, tested and commissioned within 9 days (instead of 14 days as planned and 21 days as per industry norms) MESSAGE FROM IBN-HAYYAN PRESIDENT… -----Original Message-----From: Wabli-Al, Abdulaziz A. Subject: RE: PVC DCS Upgrade Project_Mechanical Completion Notice This is a remarkable achievement. Good planning, execution, and determination paid up again. Well done guys, and many thanks to all who were involved in this job. Best Regards, aaw

47. Significant Achievements • Changeover of the system 5 days ahead of schedule • Smooth changeover without any undesired incidents Perfect Safety Record No Operational Mal-function or trip More than 18,000 wires cut, ferruled and terminated with extremely high accuracy Smooth commissioning of every UNIT of the plant

48. Significant Achievements • Changeover of the system 5 days ahead of schedule • Smooth changeover without any undesired incidents • Significant Operational and Plant Efficiency Improvements Downtime reduced significantly Batch software Enhancement resulted into increased production Operational savings by integrating dryer operations in main control room

49. Acknowledgement • YOKOGAWA is Committed PARTNER, Just not only VENDOR • Appreciation to YEA (Yokogawa Engineering Asia) • Appreciation to Yokogawa Middle East (YME) • Appreciation to Oxy-Vinyl (process Licensor) • Appreciation to Olayan Descon (Contractor) • Petrokemya Team Members (PLE, PVC Operations, CSD Maintenance, Electrical, Analyzer and Safety)

50. TEAM SPIRIT, POSITIVE ATTITUDETOTAL COMMITMENT ARE SECERETS OF PVC DCS UPGRADE PROJECT SUCCESS