Legacy System Replaced with Yokogawa CENTUM VP and ProSafe-RS at PTA plant in Indonesia

Executive Summary

PT AMI, Merak, Indonesia

PT AMI (PT Amoco Mitsui PTA Indonesia) is a joint venture between three companies BP plc. Mitsui Chemical Inc., Mitsui & Co. Ltd. The JV was established in order to support the growth of the Indonesian textile industry and is the one of the preferred and leading Purified Terephthalic Acid (PTA) suppliers in Indonesia. The plant is located in Merak within the Titan complex.

In Y2009, Yokogawa was selected by PT AMI to replace the former system with a Yokogawa DCS (CENTUM VP) and SIS (ProSafe-RS).

Customer Situation and Vendor Evaluation

PT AMI considered aligning the infrastructure and integrating various functions seamlessly for future enhancement and to obtain maximum benefits of legacy system replacement project.

For vendor evaluation, PT AMI considered the following criteria

• The reliability of the system
• Cutover risk for field wiring
• Availability of process knowledge
• Integration with the existing asset
• Dedicated and skilled local support
• Spare parts availability
• Future enhancement

Based on the above Yokogawa was selected.

The Challenges and the Solutions

Logic, CL (Control Language) and the algorithms for the reaction section are extremely complex. Yokogawa and PT AMI mutually studied the system to fully understand the PTA process dynamics. Regarding PID (proportional integral and differential) behavior, the parameters of existing system were imported into CENTUM VP without any issue and without the need for complicated calculations. Since part of LM (Logic Manager) functionality has a SIL requirement, it was migrated into ProSafe-RS safety instrumented system.

Based on the close relationship between PT AMI and PT Yokogawa Indonesia working as a team, the project was completed successfully.

Operator training
Prior to installation the PT AMI technicians were able to become familiar with the system during a two week intensive training period. This involved the technicians learning how to operate the DCS using lap top simulators.

Shutdown period
In order to keep to the project schedule, there were over 70 team members (PT AMI, Yokogawa and Sub contractors) dedicated to the site installation and cut over period. Yokogawa provided work packs (work package for efficient customer work) which allowed the project to be completed in a timely manner. Since it was necessary for part of the process to be kept operational during the shutdown period it was necessary complete the cut over within 2 hours. Yokogawa prepared temporary controllers to achieve this target.

Customer Satisfaction

Comments from Fajar Sodikin, Project Manager: "Thank you for all the support and assistance during the AMI TAR 2010 DCS/SIS Replacement project, which was completed successfully. Especially, your expertise and help have been invaluable during the commissioning and start-up, and the trouble shooting period post start up."

"Currently, our plant is in the production phase and we add/modify the control sequence for further enhancement. We created this within PT AMI and this has also worked well. It is easy to use CENTUM VP engineering environment, with continuous Yokogawa support."

Mr. Fajar Sodikin Project Manager PT AMI

Key Project Achievements

• PID parameters can be imported to CENTUM VP without complex calculation
• One-team approach with the client
• Smooth and safe cutover to the new system based on work packs
• Part of LM functionality is migrated into ProSafe-RS
• Project installation and start-up on schedule
• High level of system integrity, reliability, and quality management
• High level of customer satisfaction

<System Details>
Integrated control and safety system: CENTUM VP, ProSafe-RS
Number of hardwired I/O (DCS): 3,755
Number of hardwired I/O (SIS): 674