MOL PLC. PERFORMS SUCCESSFUL TDC 2000 HIWAY AND SAFETY SYSTEM UPGRADE AT DANUBE

Case Study OVERVIEW At ’s only crude oil refinery, a well-planned approach to control system and safety system migration extended the life of technology investments, expanded automation capabilities, and replaced legacy assets with a reliable and supportable system.

BACKGROUND Refining companies are faced with an increasingly A growing number of oil refining competitive business environment. Control system operations are under pressure to address their outdated Distributed performance and reliability can have a huge impact Control System (DCS). An older DCS on their profitability. may exhibit a host of age-related problems and failures. In addition, newer DCS technologies can impact refinery oil refinery in Hungary with a capacity MOL PLC. identified important goals profits by expanding automation of 165 000 bpd (8.1 mtpa). Its products for migration of the DCS platform at its capabilities. For these reasons, many include , chemicals, lubes and Danube facility: refinery owners/operators are looking to asphalt. The refinery employs three — Extend the life of automation perform major upgrades or even migrate crude distillation units with coking, investments to a new platform. catalytic cracking, hydrotreating, and — Replicate existing process control hydrocracking operations. MOL PLC. faced a host of challenges strategies with its existing DCS. A leading — Expand capabilities with a modern multinational oil and gas firm CHALLENGES and reliable solution headquartered in , Hungary, The MOL Danube Refinery sought to — Replace legacy assets with a MOL’s activities range from modernize its DCS technology due to supportable system exploration, production, refining, the possible negative financial and distribution, and marketing, to operational impact of utilizing an The success of the DCS upgrade production, power unsupported system. The facility was depended on maintaining the original generation, trading and dealing with an increased number of budget and meeting the limited operations. system malfunctions, as well as rising turnaround timeframe. It would be the MOL PLC.’s Danube Refinery, located at maintenance costs and an unreliable first complete DCS modernization in Százhalombatta near Budapest, began source for spare parts. recent years. The Honeywell TDC 2000 operations in 1965. It is the only crude system was installed at the refinery in 1984 and most of the legacy hardware and software was still in use. The overall project timeframe for the upgrade was set at 32 days.

MOL PLC. enlisted Honeywell’s help in bringing its control system assets up to date. Control system modernization was undertaken on the Danube Refinery’s Crude Distillation Unit 2. The project involved migrating the TDC 2000 Data Hiway to C300 controllers, upgrading Fail Safe Controllers (FSCs) to Safety Manager, and replacing all DCS marshalling and multi-core cabling (approx. 2,200 signals).

Figure 1. MOL PLC. collaborated with Honeywell to modernize its control system Refineries cannot afford a “wait and see” attitude when it comes to aging control systems. Failure to address looming obsolescence could lead to crucial assets being rendered inoperable.

event capabilities, enables easy analysis via single window access on an Experion Figure 2. Honeywell’s TÜV SIL3 certified Station, and provides the latest Safety Manager solution. generation of safety features.

The use of C300 controllers greatly The project team undertook a improves engineering productivity, comprehensive planning process. A reduces maintenance costs, and local engineering contractor prepared maximizes process uptime. These DCS specifications and detailed design modern controllers utilize a new, documents, and team members fine- powerful hardware platform while Figure 3. As demonstrated at MOL’s Danube turned the technical content, cost retaining the specific user application. Refinery, significant cost savings and estimates and schedule. Management They integrate with existing Honeywell productivity benefits can be realized from DCS modernization. approval took two months, and input/output (I/O) families and tendering required another four months. communicate with the other controllers the network. Contracts with the general contractor — Demolition time can have a and Honeywell as DCS supplier significant impact on overall project were signed seven months prior to RESULTS schedule unit turnaround. As demonstrated at the MOL — The Operator control room and Danube Refinery, significant cost the rack room was reorganized SOLUTION savings and productivity benefits and separated. Therefore, the work The MOL Danube Refinery successfully can be realized from a well-designed conditions became more ergonomic upgraded its TDC 2000 Hiway system and properly implemented control and healthy. Especially the noise to Honeywell’s latest generation modernization strategy. This includes (coming from the cooling fans of the Experion® PKS solution on an off- fewer malfunctions and reduced cabinets) were reduced significantly. process basis. The work involved direct support costs. The method of project planning, conversion of logic for FSCs to Safety MOL PLC. gained a number of valuable scheduling and implementation utilized Manager, as well as migration and insights from its control system at the Danube Refinery will be applied upgrading operator displays in the replacement project: to similar efforts at other MOL sites in Human-Machine Interface (HMI). The — Careful preparation of DCS the future. migration retained the familiarity and specification provided valuable intellectual property in new graphics. technical content Honeywell Site Support Specialists, SUMMARY responsible for maintaining the DCS, — Detailed design process helped to Thanks to control system assisted with the upgrades. ensure a proven control concept modernization, MOL PLC. elevated the — Well-defined technical documents performance of its Danube Refinery The Safety Manager system embeds eliminated ambiguity and confusion and now has a secure path forward for Honeywell expertise for integrating future upgrades. DCS reliability has — Early EPC Involvement and LEAP process safety data, applications, been improved with modern technology technologies allowed control-related system diagnostics, and critical control and plant operators are more effective items to be ordered without waiting strategies. The system integrates with an enhanced HMI. In addition, for detailed design seamlessly with Experion alarm and maintenance and support costs are lower, and control system assets are fully supported and up to date.

This successful migration project gave MOL the confidence to commit to a About Honeywell Migration Solutions much broader enterprise level service Honeywell offers a wide range of modernization solutions agreement using Assurance 360 which and Is committed enabling continuous Innovation that enable will be rolled out soon. users to leverage their foundation and focus on high value Improvements. For More Information To learn more about how Honeywell Migration Solutions can improve performance, visit www.honeywellprocess.com or contact your Honeywell Account Manager.

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