Reliance Petroleum, India Re(De)Fining Visualization for the ‘Refining Hub of the World’
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Reliance Petroleum, India Re(de)fining visualization for the ‘Refining Hub of the World’ In close cooperation with the Reliance team, Barco worked out a total visualization solution, including system design, software and hardware, configuration and integration. reliability and opera- tor comfort. In 2008, Reliance Petroleum, a subsidiary of India’s largest private sector enterprise, Reliance Industries Limited, commissioned Reliance’s second crude oil refinery, thereby catapulting the company into the premier league of the world’s largest refineries. Located in Jamnagar, on the northwest coast of India, both Reliance refineries are conveniently close to sources of oil in the Middle East and to export to all markets. To monitor, control and optimize activities at the huge Jamnagar site, Reliance set up a brand-new Refinery Control Building, featuring the largest video wall to date in the sector. Barco helped create a vision on visualization and implement it. Reliance Petroleum was set up with Barco joined the ambitious Reliance Re-writing the concept of the ambitious mission to ‘redefine life, Petroleum story in 2005, when Reliance visualization redefine growth’ by producing ultra- started conceptualizing a centralized low sulfur fuel for export to North Control Center for its new refinery com- Step one in the challenging project was America, Western Europe and Aus- plex. As Barco had supplied solutions to to create the definition for the displays, tralia. To achieve that aim, the compa- Reliance’s oil, petroleum and telecom as Reliance’s vision implied a totally ny is constantly pushing boundaries. units before, it had already established new concept of visualization, going The recently opened refinery in Jamna- a reputation for high quality, reliability much further than pixels and ergonom- gar is one of the world’s largest single- and services. The company’s track ics. Together with Honeywell and stream refinery complexes. When record with other large-size projects in Design Directions India, which were combined with the existing refinery it the oil and gas market, particularly the hired to develop the display content, forms the world’s largest refinery site. recent installations of large-size screen Reliance and Barco undertook a step- The new complex was built in the walls at the Saudi Aramco Operation wise and planned exercise to analyze record time of just 36 months, thanks Coordination Center and China EPC, fur- all plant processes, decide what aspects to Reliance’s close cooperation with ther convinced Reliance Petroleum to had to be visualized, identify the requi- world-class partners. team up with Barco for its Central Con- site visual tools and then work out a trol Center project. clear structure for the information. “As control rooms become increasingly A world benchmark centralized, they get ever more com- plex. Operators are overwhelmed by The project was certainly ambitious. data on the wall and on their desktops, Reliance Petroleum wanted to build a from all kinds of sources. This overload Central Control Center for the entire hampers real-time insight and situa- complex covering refinery, mega tional awareness, which makes the polypropylene (PP) plants and captive control process slow and error-prone,” power plants (CPP). Besides helping to said Guy Van Wijmeersch, Market Direc- monitor and control processes, the cen- tor at Barco’s Security & Monitoring divi- ter had to serve as a tool to optimize sion. To avoid this, the project team plant performance, i.e. maximize pro- decided to only visualize key perform- duction, quality, efficiency and safety, ance indicators and ensure it would be and even support business. To achieve easy to understand. that aim, high-level, next-generation information and visualization tech- niques would be needed, thereby establishing a world benchmark for refinery control rooms. In close cooperation with the Reliance team, Barco worked out a total visualization solution, including system design, soft- ware and hardware, configuration and integration. Digital Mosaic Largest wall in the industry The visualization vision was based on the Ecological Interface Design (EID con- Once the vision had been established, cept), a unique way of displaying dynamic data. “EID aims to develop a user Barco installed eight large rear-projec- interface that makes constraints and complex relationships in the work environ- tion video walls: four for Refinery and ment perceptually evident to the operators,” Van Wijmeersch continued. “The key Utilities, the other four for Power and to this interface is the graphics. If designed well, graphics turn data into useful Petrochemicals. Each wall consists of 24 information, thereby helping operators maintain excellent situational awareness, (6x4) DLP display cubes of 67" each, enhance collaboration in the working environment, understand the big picture, representing a major array of company detect incidents almost proactively, assess them and respond quickly and accu- operations. In addition, a wall of six rately before they escalate.” The Digital Mosaic Suite, which Barco had developed (3x2) 67’’ DLP modules was set up in for the Aramco Oil control room in Saudi Arabia and customized to meet the War Room. Specifications for the Reliance’s needs, played a key role in this process. Digital Mosaic is able to projection system and display image, retrieve data from a wide range of data acquisition systems, analyze it to trigger such as long lamp life, automatic cali- scenario interaction with Barco’s Apollo Wall Management Software and then bration, redundancy, ease-of-use, high visualize it on Barco’s video wall in high-quality, scalable graphics. quality, etc. were all met. The visualiza- tion solution is entirely networked through a high-speed Ethernet connec- tion, which ensures a highly available, flexible and scalable environment. Reliance fact sheet • Exporting over 1 million barrels of oil per day • 1.6% of global nominal crude processing capacity • 8 rear-projection video walls • Additional rear-projection wall in the crisis room • Counting 198 display cubes of 67” with XGA resolution • Desktop of 49152x3072 pixels visualizing all key performance indicators Knowledge makes it happen A world first Through the network, operators can Reliance Petroleum’s new Central Con- receive all possible types of data and trol room is the first refinery control video sources, which are then visual- room in the world to implement the ized in a scalable vector graphic format. concept of complete integration of Besides depicting the Reliance plants process systems with latest information (equipment and pipelines) and mission- and visualization technology, facilitating critical parameters like temperature, a high level of collaboration between volume pressure, etc., the video wall all plants and processes. By centralizing also provides more detailed process all control activities in one Control Cen- environment support, like dependen- ter, Reliance has achieved enhanced cies on upstream and downstream control and, consequently, optimized processes, constraints associated with plant performance and safety. The 60 the production process, etc. panel officers who ensure the control Quality and supervisory information room is manned 24/7, now have all the help the operators gain insight into the tools they need to acquire real-time overall performance of the plants in insight into every process and take terms of throughputs, capacity decisions promptly. utilization, material balances, yields, etc. and the current status of its equipment, while safety KPIs help keep the pulse on safety. Event-driven graphics enhance the management of Abnormal Situations, like a power or steam failure. Barco nv Pres. Kennedypark 35, B-8500 Kortrijk Europe, Middle-East, Africa: +32 56 26 20 09 USA: +1 678 475 8000 Latin America: +55 11 38421656 M30238-R01-0211-AN Japan: +81 3 5762 8727 Barco is an ISO 9001 registered company. China: +86 400 88 22726 The information and data given are typical for the equipment described. India: +91 120 4020000 However any individual item is subject to change without any notice. © February 2011 by Barco [email protected] www.barco.com/oilandgas.