Saudi Aramco Gas Plant Control System Upgrade, Haradh, Saudi…

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Saudi Aramco Gas Plant Control System Upgrade, Haradh, Saudi Arabia

In November 1999, Saudi Aramco conducted a feasibility study for its Haradh Gas Plant in Saudi Arabia for a control system upgrade, which forms part of the company's master plan system (MPS). The project was approved in July 2000 and the provisional date for commissioning and start-up of the plant is projected for late 2003. Saudi Aramco is responsible for almost all the Kingdom's extensive oil and gas operations and manages a quarter of the world's crude oil reserves. MASTER PLAN SYSTEM (MPS) The plant automation system contract is part of the MPS, a multi-million dollar multiple project with the objective to double the company's gas production and distribution capacity. A $2 billion gas processing plant is being built at Hawiyah to process 2.4 billion cubic feet per day. In addition, three existing gas plants are being debottlenecked at Shedgum, Berri and Uthmaniyah. The MGS also includes gas oil separation plants, an NGL pipeline running for more than 1,000km from the East to West coasts, as well as NGL fractionation facilities. DEVELOPMENT PROGRAMME Saudi Aramco is implementing a 25-year development programme that is costing $45 billion, and includes the construction of one major gas processing plant every five years. The Haradh gas plant will be located in the Eastern Province of Saudi Arabia. The plant is required to meet a portion of the anticipated increase in demand from the Eastern, Central and Western regions of the Kingdom. It is estimated that 1.6 billion cubic feet per day of gas will be produced during the first year of production. The facilities will also produce condensate and solid sulphur. The total expenditure envisaged for the project is just over $4 billion. Foxboro and Invensys were chosen for this project based on their proven technology, in-Kingdom support, and previous performance at three other Saudi Aramco gas plant projects: Shedgum, Uthmaniyah and Shaybah. PROCESSING CAPACITY The Haradh plant produces sales gas, condensate and sulphur, with a capacity of 1.62 billion cubic feet per day of sales gas, 141,200bpd of condensate and 90mtd of sulphur. There will be four trains with a capacity of processing 400MMSCFD to yield 375MMSCFD sales gas. Two of the trains will process the sour Haradh Khuff gas and two will process the sweet Unayzah gases. I/A SERIES CONTROL SYSTEM In its role as the process control systems (PCS) vendor, the Foxboro Company will supply and implement a Foxboro I/A series control system, a Triconex safety system, vibration monitoring systems, an operator training simulator, and a maintenance training system. In addition, Foxboro will provide transmitters and implement its gas plant applications, including compressor controls and advanced process control (APC). MONITORING AND CONTROLLING PLANT OPERATIONS The Foxboro I/A distributed control system (DCS) is used for directly monitoring and controlling plant operations. The management information system (MIS) receives real time plant data from the DCS, maintains a historical database and makes the stored data available for display and analysis. Data is also collected from the laboratory and from an IBM mainframe computer at the Saudi Aramco headquarters in Dhahran. ENGINEERING, DESIGN AND TESTING System engineering, design, staging and testing services for the project will be performed at a dedicated Foxboro project facility in East Bridgewater, Massachusetts. Site acceptance testing supervision and ongoing technical support services will be performed in-Kingdom by Invensys' Middle East organisation. LEAD CONTRACTORS Foxboro was selected as process control systems vendor. The Japanese JGC is responsible for the design, construction and commissioning of the gas plant. Technip has responsibility for all utility and offsite areas. Project Name Saudi Aramco Gas Plant Control System Location Saudi Commence 2003 Completion 25 years Estimated Investment $45 billion Capacity 1.6 billion cubic feet per day of gas Key Players N/A

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