How Automation Saved the Day for an Indian Refinery

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“Around 60 per cent of cable requirements were reduced by the use of the fieldbus multiplexer,” claimed Suryanarayana. To enhance the overall running of the plant units, P+F proposed the Advanced Diagnostic Module (ADM), which turns the physical layer/ fieldbus into a manageable asset. “The ADM automates commissioning and documentation, monitors the fieldbus segment online, and identifies faults in real-time. With ADM’s automatic tag reading users do not need to enter data twice,” said Mathew.

Suryanarayana added, “The commissioning wizard analyzes the segment after installation or maintenance work. Reports from the expert system point to installation issues, which can be resolved immediately. It also recommends limits, which are stored in the ADM. Verifying cables and nodes only requires a few mouse clicks, reducing system checkout time by more than 80 per cent. And what’s more is that this is monitored in real-time, which enables us to make well informed decisions and take immediate action.”

Digital Communication for the Whole Refinery: Benefits Attained

Following the implementation of various interface solutions, MRPL has been able to enhance the way its plant functions. Digital communication is extensively used in the automation of the refinery and has resulted in lesser instrumentation with multiple measurements being taken from single instruments.

Plant maintenance is more predictive than reactive due to the diagnostics available in the newer instruments as well as physical layer. Maintenance teams intervene less frequently and purposefully thus enabling man hour savings as well as higher availability of the system. The documentation of the control system is always readily available.

Savings have been achieved not only in terms of space but also time and efforts. Usage of advanced diagnostics for commissioning ensured greater than 60 per cent time saving on the loop check.

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