Oil & Gas · 2024 · Abu Dhabi, UAE
Downstream Refinery DCS Migration
Phased hot-cutover migration of a 30-year-old DCS across three process units with zero unplanned shutdown.
Programme scope
- Greenfield Experion PKS deployment alongside legacy DCS
- Tag-by-tag I/O migration with marshalling and validation
- Operator training simulator and graphics modernization
- SIL-2 SIS upgrade and proof-test programme
The refinery operated three interconnected process units on a DCS approaching end-of-support. We engineered a phased migration that decoupled cutover risk from production. The programme delivered modern operator workstations, alarm rationalization aligned to ISA-18.2, and a SIS lifecycle aligned to IEC 61511 — without a single unplanned outage.
