Case study Sadara
Analyzer Information Management System (AIMS)
Background
Established in October 2011, Sadara Chemical Company is a joint venture developed by the Saudi Arabian Oil Company (Saudi Aramco) and The Dow Chemical Company (Dow). It is an unprecedented undertaking – the largest chemical complex ever built in the world in a single phase, with 26 integrated world-scale manufacturing plants, over 3 million metric tons of capacity per year, and a total investment of about US$20 billion. The Sadara chemical complex is constructed in Jubail Industrial City, Saudi Arabia, and includes 1400+ process analyzers, 24 continuous emission monitoring system analyzers and 1800+ gas detectors installed throughout the complex. The process analyzers range in automation from non-intelligent to (semi-) intelligent.
Project Scope
The project scope for Hint covered supply of its commercially-of-the-shelf (COTS) software package AML Analyzer Management and delivery of all required project services for realization of a complete working system on site. The project services included software specification, design, implementation, configuration, verification, validation, documentation and startup and commissioning. AML Analyzer Management for Sadara is one of world’s largest implementations of its kind. The AML software is distributed on multiple servers, i.e. one AML Enterprise Server AML IO Servers. The AML Enterprise Server runs the AML web application and the AML central database, and provides read-only data access to the QA quality system. The IO servers are installed in separate buildings and are responsible for real-time interaction through OPC with a large set of field systems, such as DCS systems, data historians, CEMS systems, PAMC systems and GC servers.
Benefits
- Around USD 2 million in annual savings through efficient resource management
- 80% reduction of routine line samples analyzed by the laboratory
- Real-time monitoring and performance assessments of analyzers from any onsite workstation
- Insights into data trends with the ability to carry out predictive analyses, and identify and mitigate risks and emerging problems
- A data-driven, needs-based maintenance program minimizing routine maintenance costs, without sacrificing analyzer performance
- A single enterprise solution that can scale to accommodate future growth
- Automated validation management to drive higher levels of trust in analyzer results, translating into higher utilization levels of advanced process controls
- Implementation and control of Planned Preventive Maintenance (PPM) activities
- Generation of reports on alarms, KPIs, PPM activities, Control charts, etc.
