Refinery Modernization: legacy control system modernization with high-speed data analytics for real-time decision making.
Industry: Oil & Gas (Refining)
Quick Facts
| Attribute | Value |
|---|---|
| Customer | Limetree Bay Refinery |
| Location | St. Croix, U.S. Virgin Islands |
| Tags | 10,000+ communication points (licensed to 15,000) |
| Clients | 4 initial, up to 25 simultaneous (fault-tolerant redundant) |
| Development | 10 weeks initial + 6 weeks grayscale UI |
| Cost Savings | Exceeded $40,000 vs comparable solutions |
| Integrator | Control System Technologies (CSI) |
The Challenge
Challenge: Update outdated legacy software interface across refinery systems with proven design, better stability and reliability, high-quality graphics, and high-speed data analytics while maintaining operator/technician/engineer confidence during retrofit.
Specific pain points:
- Outdated legacy software across multiple systems
- Lack of high-speed data analytics for decision making
- Management relying on hearsay rather than real-time data
- Unable to analyze every point in the control system
- Unknown problems existed that couldn't be detected
- Legacy technology couldn't meet modern operational needs
Impact: Without real-time data analytics, operators couldn't identify issues before they caused unloading, runback, or shutdown events.
The Solution
Architecture
| Tier | Component | Capabilities |
|---|---|---|
| Controllers | CSI Controller, Mark 4/5/6 | Multiple gas turbines (GT-7 through GT-13) |
| Communication | OPC, ARCNET BNC Bus, GT LAN | Multi-protocol connectivity |
| SCADA | FrameworX (HMI-1, HMI-2) | High-speed data, trending, analytics |
| Analytics | OneVue + Legacy Data Recorder (LDR) | High-speed data collection, thousands of simultaneous trends |
| Servers | Fault-tolerant redundant | Primary/Secondary with automatic failover |
| Clients | Up to 25 simultaneous | Desktop visualization |
Refinery Units Covered
- Crude Units
- Vacuum Unit
- Coker
- Platformers
- Hydrotreaters
- FCC (Fluid Catalytic Cracking)
- Alkylation Complex
- ULSG Unit
- Sulfolane Complex
Data Points Captured
| Category | Examples |
|---|---|
| Pressure | Digital pressure switches |
| Temperature | Temperature switches, TCs, RTDs |
| Position | LVDTs, RVDTs |
| Speed | Speed probes |
| Vibration | Vibration probes |
| Valves | Isolation valves, control valves |
| Electrical | Diesel engine, MCCs, 13.8 kV breakers |
Scale
| Metric | Value |
|---|---|
| Communication Points | 10,000+ |
| Licensed I/O | Up to 15,000 |
| Initial Clients | 4 concurrent |
| Full Implementation | 25 simultaneous |
| Server Architecture | Fault-tolerant redundant |
Special Features
- Generator Load Control system
- Auto ISOCH Selection system
- High-efficiency grayscale color scheme
- OneVue data analytics with LDR high-speed collector
- Thousands of trends plotted simultaneously on same chart
Key Enablers
FrameworX capabilities that made this solution possible:
| Capability | Application |
|---|---|
| High-Speed Controller Data | Fast and efficient analysis of every control point |
| CSI Controller Interface | Native OPC connectivity to proprietary controllers |
| Advanced Trending | Thousands of simultaneous trends via OneVue/LDR |
| Real-Time Alarms | Prevented unloading, runback, and shutdown events |
| Fault-Tolerant Redundancy | Maximized uptime and assured access |
| Efficient Engineering | Reduced development time and cost |
The Results
$40,000+ Cost Savings — Engineering hours and upgrade cost significantly lower than comparable solutions
Real-Time Decision Making — Cold hard facts to management instead of hearsay
Prevented Shutdowns — Real-time alarms helped unit continue operation safely
Discovered Unknown Problems — Data analysis on every point found issues that didn't previously exist in visibility
Increased Efficiency & Availability — Issues resolved without shutting down, preplanned outage support
High-Resolution Analysis — Thousands of trends on same chart for root cause analysis
Simplified Operator Interface — Improved trending and data analytics for plant operations
Customer Reaction:
"When compared to their original software, the customer was overheard saying many times, 'Man, this is like magic!'."
— Ron Walker, President, Control System Technologies
Resources
Download case study: CaseStudy_Refinery.pdf
This case demonstrates refinery control system modernization with high-speed data analytics enabling real-time decision making and problem discovery.
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