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BAIJI PETROCHEMICAL COMPLEX - IRAQ

Project Description
Design and configuration of DCS and PLC based systems for three process plants as detailed below:-

Process Plant 1 – Blown Asphalt Plant (ACR)
The ACR plant consists of 5 units , i.e :-

  • Unit 108 – Bitumen processing Plant 1
  • Unit 208 – Bitumen processing Plant 2
  • Unit 150 – Tank Gauging
  • Unit 157 – Hot oil system + Hot water system
  • Unit 198 – Incinerator

Project Scope Definition:
Design, Procurement, Fabrication & Testing of:-

  • Replace relay based process interlocking system with Modicon 984 PLC (100 I/O).
  • Provide redundant ModBus communication interface to Yamatake Honeywell (host) DCS.
  • Replace existing ABB single loop controllers with Yamatake Honeywell DCS comprising of two DEO workstations, DOPC controllers and DEO I/O subsystem 480 I/).
  • Provide complete design and configuration of the DCS including 30 process graphics (including group displays) .
  • Provide panel design and build.
  • Perform FAT and deliver to site.

Process Plant 2 - Salahadin II Refinery
The SAL II plant consists of 4 units , i.e :-

  • Unit 500 – Distillation
  • Unit 600 – Light Distillate
  • Unit 700 – Gas Oil
  • Unit 800 – Reformer unit

Project Scope Definition:
Design, Procurement, Fabrication & Testing of:-

  • Replace relay based process interlocking system with redundant Modicon 984 PLC (200 I/O).
  • Provide redundant ModBus communication interface to Yamatake Honeywell (host) DCS.
  • Replace existing ABB single loop controllers with Yamatake Honeywell DCS comprising of four DEO workstations, one data historian, redundant DOPC controllers and DEO I/O subsystem 1200 I/O).
  • Provide complete design and configuration of the DCS including 100 process graphics (including group displays) , 140 loops (of which 60 are advanced control loops)..
  • Provide panel design and build.
  • Perform FAT and deliver to site.

Process Plant 3 - Lube Oil Plant
The lube oil plant was the biggest system to be replaced. It comprised of two process trains, one of which was upgraded as part of this project (the Lube oil plant comprised of 7 units of which only 5 of these were upgraded ), i.e :-

  • Unit 101
  • Unit 102
  • Unit 103
  • Unit 104
  • Unit 105

Project Scope Definition:
Design, Procurement, Fabrication & Testing of:-

  • Replace relay based process interlocking system with redundant Modicon 984 PLC (450 I/O).
  • Provide redundant ModBus communication interface to Yamatake Honeywell (host) DCS.
  • Replace existing ABB single loop controllers with Yamatake Honeywell DCS comprising of eleven DEO workstations, one data historian, redundant DOPC controllers and DEO I/O subsystem for 2400 I/O).
  • Provide complete design and configuration of the DCS including 150 process graphics (including group displays) , 237 loops (of which 100 are advanced control loops).,
  • Supply and install Fibre Optic communication between DCS in Process Control Room and DCS in satellite instrument houses 11 and 12.
  • Provide panel design and build
  • Perform FAT and deliver to site