PETROBEL- Abu Madi S5-155H Migration System Expansion & Modernization PETROBEL, a leader in Egypt’s oil processing industry, initiated a major expansion and modernization of its legacy S5-155H control system at the Abu Madi facility. The project aimed to eliminate obsolete single-loop controllers, enhance the SCADA system’s capabilities, and integrate new processes into the centralized control […]
PETROBEL, a leader in Egypt’s oil processing industry, initiated a major expansion and modernization of its legacy S5-155H control system at the Abu Madi facility. The project aimed to eliminate obsolete single-loop controllers, enhance the SCADA system’s capabilities, and integrate new processes into the centralized control architecture. MISC provided a comprehensive, turnkey solution to replace aging hardware with a modern, scalable, and high-availability automation platform.
• Core System Upgrade: Replacement of obsolete Kent Tieghi P4000 single-loop controllers and alarm panels with a new, redundant Siemens S7-400H PLC and distributed ET200M I/O stations, integrating 65 redundant PID loops.
• Ancillary System Integration: Design and supply of two new Siemens S7-300 PLC-based control systems for Compressors 34 A/B and a new interface module to integrate the Heater station into the main SCADA.
• SCADA & Server Infrastructure Enhancement: Upgrading the existing WinCC SCADA for two workstations and expanding the system with a redundant server rack for data integrity, an extra operator workstation, and supporting network switches and printers.
• Full Lifecycle Services: Comprehensive engineering, documentation, FAT/SAT, on-site commissioning, and extensive training for both operators and engineers.
• Elimination of Technological Obsolescence: Phased out unsupportable single-loop controllers and indicators, centralizing control into a modern, maintainable PLC/SCADA platform.
• Significant Enhancement of System Reliability: The redundant S7-400H architecture and hot-swappable I/O modules ensured maximum uptime for critical oil and gas processes.
• Unified Operational Overview: The upgraded and expanded SCADA system provided operators with a single, integrated view of the entire process, including the new compressors and heater, replacing disparate panels with advanced graphics, faceplates, and centralized alarming.
• Future-Proof Scalability: The design included 25% wired I/O spares and 25% free panel space, and the robust server/client architecture allowed for effortless future expansions and modifications.
This strategic, comprehensive expansion by MISC successfully modernized PETROBEL’s control infrastructure, extending the lifecycle of the automation system. The project enhanced operational efficiency, provided greater process insight, and ensured long-term reliability and supportability for the Abu Madi facility’s core operations.
Redundant Siemens S7-400H PLC + ET200M Remote I/O
+ Siemens S7-300 PLCs for Compressors
+ Redundant Server Rack & Extra Workstation
