Case Studies

🛢️ Oil & Gas

ARAMCO Upstream Facility DCS Migration

Saudi Aramco · Dhahran, Eastern Province

45%Efficiency Gain
ZeroUnplanned Stops
$3.2MAnnual Savings
Challenge

Legacy DCS (15+ years old) across 4 production trains with unsupported hardware, growing cybersecurity risk, and difficulty finding spare parts. Migration required zero unplanned downtime during active production.

PowerSolutions Approach

Phased Siemens PCS 7 migration with parallel-running cutover strategy. Custom migration tools preserved all 14,000 control narratives. FAT completed in 8 weeks; full SIT with zero production interruption.

DCS Migration Siemens PCS 7 SIL 2
🧪 Petrochemicals

SABIC Plant MES & OEE Optimization

SABIC · Jubail Industrial City

32%OEE Improvement
18%Scrap Reduction
$1.8MAnnual Value
Challenge

3-line polymer production plant with no real-time production visibility, manual quality records on paper, and no ERP connectivity. Management had no live OEE data and quality traceability was manual and error-prone.

PowerSolutions Approach

PowerMES deployment across all 3 lines — integrated directly with existing SAP S/4HANA. Real-time OEE dashboards on shop floor screens. Electronic batch records replacing all paper. Quality management alerts with automated SPC charts.

PowerMES SAP Integration OEE Analytics
🏭 Manufacturing

MAADEN Mining Smart Factory IIoT

Ma'aden · Wa'ad Al-Shamal, Northern Borders

60%Fewer Breakdowns
$2.1MAnnual Savings
200+Devices Connected
Challenge

200+ motors, pumps, and compressors across remote phosphate mining facility with reactive-only maintenance. Unplanned breakdowns causing 120+ hours/year of lost production. No connectivity between field assets and central operations.

PowerSolutions Approach

IIoT Gateway G3 deployed on all critical assets. Vibration, temperature, and current signatures collected. Edge AI models trained on 6 months of historical data identified bearing wear 3 weeks in advance. Maintenance shifted from reactive to predictive.

IIoT Gateway G3 Edge AI Predictive Maintenance
⚡ Utilities

SEC Power Plant SCADA Modernization

Saudi Electricity Company · Riyadh Region

28%Energy Reduction
99.97%SCADA Uptime
4× FasterAlarm Response
Challenge

Legacy SCADA from 2005 with poorly designed alarm floods (8,000+ alarms/day), limited visibility across 3 substations, and outdated Windows XP-era operator workstations. Cybersecurity audit had flagged critical OT vulnerabilities.

PowerSolutions Approach

Full SCADA replacement with Inductive Automation Ignition. ISA 101 high-performance HMI redesign reduced nuisance alarms by 85%. ISA 18.2 alarm rationalization. Secure DMZ architecture with IEC 62443-compliant segmentation. Remote monitoring enabled from SEC control centre.

SCADA / HMI ISA 18.2 OT Cybersecurity
Aggregate Impact

Our Numbers Tell the Story

500+

Projects Completed

45%

Avg. Efficiency Gain

$500M+

Client Value Created

98%

Client Retention Rate

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