Modernizing Supervision: The Challenge of a Critical Petrochemical Complex
In the Middle East, Comeca carried out a complete modernization of the supervision system at a major petrochemical site. Originally designed in 2012, the installation required a comprehensive upgrade to eliminate obsolescence risks and meet current cybersecurity standards. The project involved updating all hardware and software while preserving the site's historical production data.
A Large-Scale System Reaching Maturity
The industrial site relies on a large-scale automation and electrical distribution architecture: 21 electrical substations, 50 power switchboards, 21 pairs of Siemens PLCs, and thousands of signals processed continuously. After more than ten years of operation, the system was facing obsolescence risks. Aging IT hardware and the original operating systems (Windows 7 and Windows Server 2008) were no longer receiving security updates. For the operator, the objective was to modernize the supervision system without causing prolonged disruption to operations and without losing historical archive data.
Preparation Based on Virtualization
To secure the operation and validate the compatibility of the various software components, the engineering teams implemented a rigorous methodology:
- Full virtualization: Reconstruction of the original environment using site backups to test operating system migrations.
- Software upgrade: Migration of the supervision system to Siemens SIMATIC WinCC V8.1, running on Windows 11 Enterprise and Windows Server 2022.
- Data preservation: Secure conversion and transfer of archive databases and specific display modules.
- Factory Acceptance Testing (FAT): Rigorous validation of the new system on a test bench in the presence of the customer prior to shipment.
A Controlled On-Site Installation
The replacement of the legacy computers with latest-generation HP servers and workstations was carried out directly on site by the local Comeca Middle East teams. The intervention procedure enabled the old equipment to be removed and the new infrastructure to be brought online while keeping system downtime to an absolute minimum.
The operator now benefits from a modern, secure, and future-proof supervision system, supported by a new hardware infrastructure designed for the next ten years.
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