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REFAP Refinery

Development of the REFAP Distributed Control and Monitoring System (SCMD)

Altus was responsible for designing and implementing the Distributed Control and Monitoring System (SCMD) at REFAP – the Alberto Pasqualini Refinery, part of Petrobras.

Optimized supervision and control

For the electrical systems, Altus' solution supervises and controls equipment such as substation circuit breakers, disconnect switches, transformers, and associated protections. It manages load rejection and reacceleration, demand control, power factor regulation, and sequential event logging at 1 ms intervals. On the thermal side, it supervises steam generation and cooling systems, interfacing with multi-loop controllers to manage boilers.

The system also handles transfer and storage operations, supervising and controlling pumps, tank agitators, motorized valves, and other actuators. It executes PID loops for flare control and integrates with tank level and temperature transmitters. Additionally, this solution allows the system to monitor and control distillation processes, communicating with motors and other actuators via MODBUS.

Panel Modernization

Reduction in space and wiring, resulting in increased reliability, cost savings, and enhanced supervision and control capabilities

Remote Operation

Reduced human risks in local operations and optimized response times during emergencies

Control and Supervision

Comprehensive control and supervision of motors connected to the SCMD's input and output points

Seamless Integration

An open architecture design ensures easy integration with third-party equipment and protocols

Escopo de equipamentos utilizados no projeto

Equipment Overview Used in the Project

- Programmable Controllers AL-2002/MSP: 37
- 2 redundant PLCs for load rejection, demand control, and power factor regulation using AL-2005 coprocessors
- 5 PLCs with AL-2005 coprocessors to interface with other equipment
- FIX-DMACS supervision stations: 17
- Gateways AL-2400/S (ALNET I/ALNET II): 17
- Gateways AL-2798 (MODBUS/ALNET II): 4
- Bridges AL-2401 (ALNET II/ALNET II): 26
- Optical modems AL-2410: 99

Redes e recursos de comunicação utilizadas no Projeto

Communication Networks and Resources Used in the Project

- ALNET II process network: implemented with RS-485 electrical cabling or redundant fiber optics. This deterministic, multi-master 1 Mbps network connects the programmable controllers and Altus gateways to the supervision stations, structured into multiple independent sub-networks via bridges
- ALNET I network: links the supervision stations to the ALNET II network via gateways, supporting unsolicited messages
- Ethernet network: connects the supervisory stations to each other and to REFAP’s corporate network
- MODBUS network: connects the ALNET II network to the Fisher Controls DCS via gateways
- Interfaces with intelligent transmitters and multi-loop controllers through Altus PLC coprocessors

Características específicas da aplicação

Application specifics

- I/O Count: 10,000 digital and 500 analogs
- Supervision software: Fix Dmacs for Windows
- Special features: Ethernet/TCP-IP, load rejection, priority messaging, integration across multiple communication networks (7 types), over 30 sub-networks, fiber optic communication (FOCOS system), interface with the refinery’s DCS via MODBUS protocol