Study, Design, and Development of an Integrated Control and Safety System (ICSS) for an Oil Processing Unit with AI-Based Predictive Maintenance

Department

Automation department — Project 03/06 of the Integration Objects PFE Book 2026–2027.

Project

Architect an Integrated Control and Safety System (ICSS) for an oil processing site, covering safety interlocking, automation cabinets, and supervisory HMIs. The project also includes the integration of an AI-based predictive-maintenance model into the SCADA system.

Objectives and responsibilities

• Compare automation architectures and industrial communication protocols, including OPC and Modbus.
• Analyze engineering design input packages and Cause & Effect matrices.
• Develop the general system architecture and industrial network design.
• Design control-system cabinets and wiring diagrams.
• Develop and implement process-control and interlocking logic.
• Create SCADA/HMI graphics and synoptics.
• Integrate an AI-based model into the SCADA system to analyze real-time telemetry data, detect anomalies, and identify abnormal operating patterns.

Keywords

PLC, predictive maintenance, SCADA, OPC, Modbus, AI, oil and gas, Python, Machine Learning, Java scripting.