GASCO Achieves Plant Information Integrity with Intergraph® SmartPlant® Enterprise

Abu Dhabi Gas Industries Ltd. (GASCO) is the operating company in Abu Dhabi responsible for processing onshore natural gas and associated gas from onshore oil production fields. Intergraph® SmartPlant® Enterprise (SPE) helped GASCO consolidate three plants into one centralized enterprise system by using, SmartPlant Foundation (SPF) and an engineering applications database.

The Challenge

With a process capability of 8 billion standard cubic feet of feed gas (BSCFD) per day and producing 280,000 barrels of condensate, 6,800 tons of sulphur, and 44,000 tons of NGL per day, GASCO is currently one of the largest gas processing companies in the world.

GASCO’s industrial complex, one of the biggest in the United Arab Emirates, is composed of four desert plants – Asab, Bu Hasa, Habshan, and Bab and Ruwais – and a pipeline network which process and deliver a range of marketable products such as methane (C1), to industrial customers; ethane (C2), to Borouge; and propane (C3), butane (C4), paraffinic naphtha (C5+), granulated sulfur, and condensate, exported all over the world.

GASCO’s priority is to maximize production in the most cost-effective manner, while maintaining the highest possible standards of industrial safety and protection of the environment. To ensure that its production meets growing energy demand, Gasco decided to invest in building a robust, centralized, and integrated plant engineering management system for information integrity and to ensure that all plant drawings are as-built.

Gasco adopted Intergraph SmartPlant Enterprise as a standard to:

  • Consolidate three plants into one centralized enterprise system, using, SmartPlant Foundation (SPF) and an engineering applications database
  • Create a robust SPF integrated with SmartPlant engineering applications infrastructure with high availability
  • Standardize SmartPlant Enterprise latest release and SmartPlant engineering applications
  • Unify SPF schema and SmartPlant P&ID (SPP&ID), SmartPlant Instrumentation (SPI), and Smart 3D Data Dictionary
  • Create new standard Major Projects/B-13 Automation Plan
  • Enable the integration of SPF, Maximo, and Open Text ECM

Ensuring a successful migration to SmartPlant Enterprise required some infrastructure and organizational changes.

An engineering numbering procedure (plant breakdown structure, documents and tags) was established to ensure accuracy and consistency of data and documents. Life-cycle information requirements were listed (documentation for operations) and the contractors’ scope of work was defined. It was important to identify one EPC responsible to deliver the SmartPlant Enterprise deliverables. This ensured leadership and appropriate coordination. It also provided early access to handover of data and documentation, with early access to compliance review and validation and verification of deliverables. To ensure everyone understood the changes, awareness and training sessions were set up, including workshops for senior management and training for designers and end users.

The implementation of the Major Projects Automation Plan was executed by establishing data and document standards, procedures, and workflows. These included data validation before handover, plant testing, and security audits conducted before handover, as well as creating a proper backup. Follow-up with EPC contractors during the project was essential to success.

The Solution

Currently, all plants are standardized and unified on SPF and related SmartPlant Engineering Applications. The PBS hierarchy structure for the new system is complete and a unified SCHEMA file for SPF has been created. A new files database was created for SPPID, SPI, and Intergraph Smart™ 3D. All SPE hardware and software infrastructure setup was completed. The company’s major projects automation plan is up and running, enabled by upgraded SPPID and SPI engineering applications and publishing systems.

The business benefits include quicker and easier retrieving of information; engineering data is shared between applications and users; and the company has better control of all plant modifications requests through SPF Engineering Change Management, as well as better control of the engineering processes workflow. Intelligent 3D models, data, drawings, and documents are up to date and navigation between 2D documents and 3D models is easier and faster. Consolidated and aggregated data from multiple heterogeneous sources provide a ‘single reliable source of the truth,’ which increases efficiency and ultimately reduces costs.