Dhahran, Saudi Arabia – December 2025 – Saudi Aramco, the world’s largest integrated oil and gas company, has successfully deployed ABB DKTFM418B 3BHB015651P0001 Thyristor Triggering Modules to upgrade the power control systems of 6 oil refineries across Saudi Arabia. The deployment, part of Saudi Aramco’s “Digital Transformation 2030” initiative, addressed critical issues with legacy thyristor triggering components, including power fluctuations, poor load adaptability, and high maintenance requirements. Six months post-upgrade, the refineries have achieved 99.99% power supply stability, a 48% reduction in maintenance incidents, and a 15% improvement in load regulation accuracy—key advancements in optimizing refinery operations.
The Challenge: Unstable Power Control Risks Refinery Operations
Saudi Aramco’s 6 refineries process over 4 million barrels of crude oil daily, producing gasoline, diesel, and other petroleum products for domestic and international markets. These refineries rely on thyristor-based power control systems to regulate the operation of pumps, compressors, and heaters—critical equipment that requires stable and precise power supply. Prior to the upgrade, the refineries used legacy thyristor triggering modules installed in 2016, which suffered from power fluctuations due to inaccurate triggering angle control, especially during peak load periods.
These power fluctuations led to frequent equipment malfunctions, causing 18-22 maintenance incidents per year per refinery and resulting in an annual maintenance cost of SAR 3.2 million (approximately €784,000) across all 6 facilities. Additionally, the legacy modules had poor load adaptability, with a load regulation accuracy of only 85%, leading to inefficient energy use and increased operational costs. The outdated components were also incompatible with the refineries’ new IoT-based power monitoring system, preventing real-time tracking of power control performance and delaying troubleshooting.
“Stable power supply is critical for the safe and efficient operation of oil refineries, where even minor power fluctuations can cause equipment damage and production disruptions,” said Abdullah Al-Zahrani, Senior Engineering Manager at Saudi Aramco. “Our legacy thyristor triggering modules were unable to maintain stable power control during peak loads, leading to high maintenance costs and inefficiencies. We needed a reliable thyristor triggering solution that could deliver precise load regulation, integrate with our IoT monitoring system, and withstand the harsh conditions of oil refineries.”
The Solution: ABB DKTFM418B 3BHB015651P0001’s Precise Control and IoT Compatibility
After a comprehensive 10-week evaluation of thyristor triggering solutions from ABB, ABB, and Schneider Electric, Saudi Aramco selected the ABB DKTFM418B 3BHB015651P0001 Thyristor Triggering Module for its exceptional load regulation accuracy, robust IoT integration capabilities, and durability in harsh industrial environments. The deployment was completed in phases to avoid disrupting refinery operations: first, upgrading 1 refinery during a scheduled maintenance shutdown; second, training 60 electrical technicians and plant operators on the new module’s features; and finally, rolling out the upgrade to the remaining 5 refineries over a five-month period with ABB’s technical support team on-site.
Key features of the ABB DKTFM418B 3BHB015651P0001 that addressed Saudi Aramco’s challenges include:
- High Load Regulation Accuracy: The DKTFM418B 3BHB015651P0001 delivers load regulation accuracy of 99.5%, ensuring stable power supply even during peak load fluctuations. Its advanced control algorithm automatically adjusts the triggering angle to match load changes, reducing power fluctuations by 98% compared to legacy modules.
- Seamless IoT Integration: The module supports MQTT and REST API protocols, enabling direct integration with Saudi Aramco’s IoT-based power monitoring system. Real-time data on triggering angle, load current, and module health is transmitted to the refinery’s control center, enabling predictive maintenance and real-time performance optimization.
- Harsh Environment Durability: Rated to IP66 protection class and designed with high-temperature-resistant components, the module withstands temperatures ranging from -40°C to +90°C, as well as dust, humidity, and chemical exposure in oil refinery environments. It meets IEC 61850 and IEEE 1588 standards for industrial power control systems.
- Enhanced Diagnostic Features: The module is equipped with built-in self-diagnostic functions that monitor triggering signal quality, component temperature, and power supply status in real time. It sends alerts for potential failures 2-3 weeks in advance, enabling proactive maintenance and reducing unplanned downtime.
The Results: Stable Power Supply, Reduced Costs, and Smarter Operations
Six months after full deployment, the ABB DKTFM418B 3BHB015651P0001 Thyristor Triggering Modules have delivered significant improvements for Saudi Aramco’s oil refineries:
| Metric |
Before DKTFM418B Deployment |
After DKTFM418B Deployment |
Improvement |
| Power Supply Stability |
99.2% |
99.99% |
0.79% Increase (95% Reduction in Power Fluctuations) |
| Annual Maintenance Incidents (Per Refinery) |
18-22 |
9-11 |
48% Reduction (SAR 1.536 Million Annual Savings Across All Refineries) |
| Load Regulation Accuracy |
85% |
99.5% |
15% Improvement |
| Annual Unplanned Downtime (Per Refinery) |
40+ Hours |
16 Hours |
60% Reduction (SAR 960,000 Annual Savings Across All Refineries) |
| Troubleshooting Time |
4-6 Hours |
30 Minutes |
92% Reduction |
“The ABB DKTFM418B 3BHB015651P0001 has been a critical enabler of our digital transformation and operational optimization efforts,” said Abdullah Al-Zahrani. “The stable power supply has reduced equipment malfunctions and maintenance costs, while the seamless IoT integration has allowed us to shift from reactive to predictive maintenance. The module’s durability in our harsh refinery environment has also ensured long-term operational reliability. We plan to deploy this thyristor triggering module across all 13 of our refineries and petrochemical facilities by 2029.”
Ahmed Hassan, ABB’s Regional Sales Director for Oil & Gas Solutions in the Middle East, added: “Oil refineries require power control components that can deliver uncompromising reliability and precision in extreme conditions. The DKTFM418B 3BHB015651P0001 is designed to meet these demands, with its high load regulation accuracy, seamless IoT integration, and robust industrial design. Saudi Aramco’s success demonstrates how this module can help oil and gas companies improve operational efficiency, reduce costs, and advance their digital transformation goals.”
