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Safety Solution

New Comprehensive Safety Solution Enhances QAPCO Plant Safety and Availability

| Editor: Dr. Jörg Kempf

QAPCO’s newest facility is able to produce 300,000 metric tons of LDPE per year, increasing the company’s annual production of LDPE to 700,000 metric tons per annum.
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QAPCO’s newest facility is able to produce 300,000 metric tons of LDPE per year, increasing the company’s annual production of LDPE to 700,000 metric tons per annum. (Picture: Qatar Petrochemical Company (QAPCO) QSC)

To support the expansion of its plants producing low density polyethylene (LDPE) and other petrochemicals, Qatar Petrochemical Company (QAPCO) chose a comprehensive safety solution. The Hima solution supports emergency shutdown (ESD), fire & gas (F&G) and furnace control as well as seawater cooling applications.

Bruehl/Germany – In total, 13 safety controllers were integrated with a Honeywell distributed control system (DCS) as part of an expansion project that included new construction, plant renovation and equipment retrofitting. Communication between the Honeywell DCS and the Hima safety controllers is accomplished via Modbus TCP Master & Slave protocol.

Two HIMax systems and 11 HIQuad systems, together supporting approximately 5,000 I/Os, replaced a conventional relay-based safety system and PLCs. The Hima controllers are certified to SIL 3 as per the IEC 61508/IEC 61511 standard.

QAPCO relied on Hima for a range of services supporting the project, including:

  • training,
  • basic engineering,
  • DCS integration,
  • factory acceptance testing (FAT),
  • system installation and testing,
  • start-up and functional tests under operating conditions,
  • TÜV approval.

A Hima customer since 1995, QAPCO chose the Hima solution for its contributions to safety, plant availability and system reliability and its ability to monitor all process parameters and easily identify the cause of a plant failure. “Hima products are very reliable, but we count on Hima for more than products”, says Ahmed Ezz El Dine Mohamed Refaat, Head of QAPCO’s Automation & Electrical Section. “We consider them as a total solution provider.”

QAPCO is a joint venture between Industries Qatar (80 %) and Total Petrochemicals (20 %). Considered as one of the region’s largest producers of LDPE, QAPCO also produces ethylene, sulphur and other petrochemicals.

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