Located within PlasChem Park in Jubail Industrial City, Saudi Arabia, Veolia's flagship 'Tahwil' facility stands as a premier regional benchmark for hazardous industrial waste treatment. Operating under strict environmental protocols aligned with Saudi Vision 2030, the plant safely destroys over 121,000 tonnes of toxic waste annually at temperatures exceeding 1,100°C, simultaneously operating as a waste-to-energy powerhouse generating 40 tonnes of steam per hour for nearby industrial partners.
In partnership with ABB Saudi as the EPC, our engineering leadership was enlisted to orchestrate the final engineering, systems integration, and commissioning of the facility's complex Integrated Control and Safety System (ICSS).
Architecture Standardization & Field Remediation
Because the project's automation logic had previously transitioned through multiple programming teams, the codebase suffered from severe fragmentation. We initiated a comprehensive architectural overhaul, conducting a rigorous audit of the Philosophy of Operation alongside the core process team. After rectifying foundational logic flaws, we standardized all object classes, control modules, and HMI graphics to ensure a cohesive and highly deterministic operating environment.
- Redundant 800xA ICSS Deployment: Successfully deployed a highly available control network utilizing four AC 800M process automation controllers and one dedicated SIS controller for critical safety interlocks.
- Complex Equipment Integration: Programmed sophisticated thermodynamic control logic for the primary rotary kiln, high-temperature burners, heat recovery steam generators (HRSG), and extensive chemical tank farms.
- Field I/O Remediation: Discovered and resolved critical field wiring discrepancies caused by underperforming termination contractors, systematically re-allocating and mapping over 5,000 I/O loops to restore absolute signal integrity.
- Third-Party Subsystem Connectivity: Integrated multiple complex vendor packages directly into the 800xA central command architecture for unified, plant-wide visibility.
- Seamless Final Startup: Delivered a flawless commissioning sequence, transforming a troubled automation baseline into an enterprise-grade, highly optimized industrial asset.
