Project Scope

The project involves the design, supply, installation, and commissioning of instruments and Remote Input/Output (IO) panels for the automation of the lube oil clay-less finishing process at Mari Petroleum.

Background:

Mari Petroleum Company Limited (MPCL), established in 1984, is a leading producer of base oil with various grades derived from waste lubricating oil and other suitable waste oils. Traditionally, the lube oil recycling process utilized clay, resulting in significant environmental pollution. To mitigate this issue, MPCL required an environmentally friendly process for refining lube oil. A USA-based consultant designed the new plant, and FAIZAL was selected as the contractor for Control System and Instrumentation operations.

System Description:

FAIZAL provided a comprehensive automation solution for two critical sections of the plant: the reactor and evaporation sections. The instruments and equipment used in these sections are rated for explosion-proof environments to ensure safety and compliance with industry standards.

System Architecture:

The automation system for the lube oil clay-less finishing process includes the following components and functionalities:

1. Instrumentation:
   • Vega: Level transmitters and vibrating level switches for precise level measurement and control.
   • General Instruments: Level, pressure, and temperature gauges for accurate monitoring of process parameters.
   • Fuji Electric: Pressure transmitters and differential pressure flow transmitters for reliable pressure measurement and flow monitoring.
   • Samson: Pressure reducing valves to regulate pressure within the system.
   • Burkert: Ball valves for efficient fluid control.
   • Leser and Motherwell: Pressure safety valves to ensure safety by preventing overpressure conditions.
   • Danfoss: Pressure switches for critical pressure monitoring and control.
   • Toshniwal: Oval wheel meters for accurate flow measurement.
2. Control System:
   • The system uses the Mitsubishi Electric MELSEC iQ-R Series Programmable Logic Controller (PLC) with Input/Output (I/O) modules. The PLC is the core component, responsible for data acquisition, processing, and control.
   • The PLC gathers data from the reactor section, evaporation section, and Motor Control Center (MCC) through Remote IO (RIO) modules. This data is then communicated to the central Supervisory Control and Data Acquisition (SCADA) system for real-time monitoring and control.
3. Communication Network:
   • The stations are interconnected with the central control room via the CC-LINK IE FIELD Network, a high-speed, industrial Ethernet-based network ensuring seamless communication and data transfer.
   • A heater PLC is also integrated into the central system using the CC-LINK network, allowing for comprehensive control and monitoring.
4. SCADA System:
   • The central SCADA system provides a comprehensive visualization of the entire process, enabling operators to monitor and control the system efficiently.
   • The system is designed to generate visual alarms with prioritized visibility based on criticality, ensuring timely responses to any issues.
   • Data logging is implemented for designated inputs, with a user-selectable interval time for effortless and quick data measurement and recording. The data logging feature allows for thirty days of data storage before automatic deletion of logged charts.
   • Trend analysis is included in the SCADA system, enabling users to analyze production data with user-adjustable time intervals. This helps in optimizing the production process and identifying areas for improvement.
   • Access privilege features are incorporated, enabling specific access rights for each user. Depending on the logged-in user and their access rights, parameters such as set points can be adjusted. Access rights and privileges are also set up to manage alarms and process control.

Project Outcomes

The successful execution of this automation solution by FAIZAL provided Mari Petroleum with a reliable and stable control system for their lube oil clay-less finishing process. The environmental benefits of this new process, combined with enhanced production efficiency and improved monitoring and control capabilities, have significantly improved the operational performance of the plant. The flexibility and reliability of the upgraded system ensure that Mari Petroleum can adapt to future requirements and continue to maintain high standards in their production processes.