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Indian Oil Company Limited, Uttar Pradesh, India
The Mathura refinery is a strategically important facility that supplies diesel, gasoline, aviation turbine fuel, kerosene, liquefied petroleum gas, furnace oil, and bitumen to customers throughout northwestern India. The sixth refinery to be built by the Indian Oil Company Limited (IOCL), it had an initially capacity of 6.0 MMTPA at the time of its commissioning in 1982. Originally configured with facilities that included crude oil distillation (CDU), vacuum distillation (VDU), vis-breaker (VBU), and Merox process units, this refinery was revamped beginning in 1999 with the installation of a diesel hydro desulphurization unit (DHDS) licensed from the French firm Axens, for the production of high speed diesel (HSD) fuel with a low sulphur content of 0.25% (maximum).
A once-through hydrocracker (OHCU) and a hydrogen generation unit (HGU) were added on in 2000, increasing the plant's capacity to 8.0 MMTPA. As part of this plant revamp, a new distributed control system (DCS) and safety instrumented system (SIS) were installed to control both the originally configured and newly introduced units at this refinery.
In 2013, Yokogawa India was commissioned to carry out a revamping of the control and safety systems at the Mathura refinery. This project involved the design, engineering, installation, and commissioning of a CENTUM VP distributed control system (DCS) and a ProSafe-RS safety instrumented system (SIS) to replace the refinery's legacy systems. The project scope included the removal of the legacy DCS and the design, engineering, installation, and commissioning of an integrated CENTUM VP DCS and ProSafe-RS SIS solution. All this work was done on a tight schedule, while the refinery was shut down for routine maintenance.
Before and after revamp photos of the central control room (CCR).
Before
After
The CCR layout was jointly designed by IOCL and Yokogawa India. The number of consoles was increased to improve efficiency.
With the aim of having minimal re-engineering of control loops and ensuring the commissioning of the units on the first attempt, Yokogawa and IOCL's engineers worked closely together to expedite the following tasks:
All installation work was completed, units were powered on, loops were checked, commissioning was completed, and stable operation was achieved in a span of just 19 days - one day ahead of schedule.
The following key parameters were provided by IOCL as benchmarks for this project and each was met by Yokogawa India:
New system | |
System tags | 23,800 |
Field control stations (DCS controllers) | 28 |
Safety control stations (ProSafe-RS) | 11 |
Human machine interface stations | 23 |
DCS engineering stations | 4 |
SIS engineering stations | 4 |
Other stations (*) | 14 |
(*): Historical data stations, OPC interface stations for 3rd party systems, alarm information and management stations, documentation node (DON) stations, sequence of events (SOE) stations
With careful planning and implementation, Yokogawa can help you achieve a safe, cost-effective, and value-added hot or cold cutover migration process for your system.
The ProSafe-RS is a Safety Instrumented System that is certified by the German certification organization (TÜV) to meet Safety Integrity Level (SIL) 3 specified in IEC 61508.
Our distributed control system (DCS) enables automation and control of industrial processes and enhanced business performance. Over 10,000 plants entrust Yokogawa DCS to deliver their production goals.
Contact a Yokogawa Expert to learn how we can help you solve your challenges.