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Habshan 5 — a gas processing and sulphur production facility
By our business bureau July 05, 2012
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SHARJAH: Habshan-5, a gas processing and sulphur production facility of Abu Dhabi Gas Industries (GASCO), 90 per cent of which was completed by the end of May 2012, is now processing 1,000 million scfd of offshore gas from Umm Shaif and an additional 1000 million scfd of onshore gas comprising a mix of associated gas from ADCO and non-associated high sour gas from the Habshan fields.

The project is a government initiative to help meet growing demand for gas resources within the UAE. The project includes a gas processing plant, a sulfur recovery unit, and a natural gas liquids (NGL) recovery unit.

The mega project was scheduled to be completed in 50-month contractual period, in the third quarter of 2013, but the goal was achieved in 33 months, 17 month ahead of the maturity time.

This, the company attributes to good business planning, management creativity and team work.

Companies involved in the Habshan 5 project included JGC, Maire Tecnimont, Fluor and Kuwait’s Kharafi National.

The Abu Dhabi Gas Industries (GASCO) had awarded the contracts for Engineering, Procurement, Construction and Commissioning (EPC) works for the Integrated Gas Development (IGD) Project on Lump Sum Turn key Basis, covering the packages: Habshan 5 Process Plant; Habshan 5 Utilities & Offsites (U&O); Ruwais 4th NGL Train; and Ruwais Storage Tanks.

Habshan 5 Process Plant was awarded to a joint venture of JGC of Japan and Tecnimont of Italy.

Habshan 5 U&O was awarded to Hyundai Engineering & Construction of South Korea.

Ruwais 4th Natural Gas Liquids (NGL) Train was given to a joint venture of Petrofac of the UAE and GS Engineering of South Korea.

Ruwais Storage Tanks work was awarded to CBI of USA.

The Letters of Award were issued to the Companies on July 15, 2009.

The initial phase of the projects execution commenced from the respective contractors’ home offices and later moved to the respective sites at Habshan and Ruwais for construction activities.

There are four gas processing trains with total processing capacity of 2,000 MMSCFD. Of this, 1,000 Million Standard Cubic Feet Per day (MMSCFD) of gas is being transported from offshore field Umm Shaif via Das Island to enable ADMA-OPCO to meet their planned increase in oil production. The remaining 1,000 MMSCFD of gas comprises of a mix of Associated Gas as a result of increase in Oil Production by ADCO from 1.4 to 1.8 MM barrels/day and non-associated gases of high sourness from Habshan gas fields.

Gas is drawn from Abu Dhabi Marine Operating Company’s (ADMA-OPCO’s) Umm Shaif offshore field, where NNPC last month was awarded the EPC contract to construct the upstream part of the IGD project, by drilling the required production wells, installing a production and dehydration platform, and tying the production in to the onshore facilities. Abu Dhabi is struggling-like many of its neighbours-to keep abreast of its own spiralling domestic gas demand situation, with projects like these necessary to meet the expected demand by the time they come fully onstream.

Four new sulphur recovery unites have also been built at the Habshan 5 complex which have a recovery efficiency of upto 99.9 per cent reducing the emission of toxic gases considerably and meeting the environment standards of ADNOC.

At the time of award of the projects, GASCO had direct its contractors to maximise in these projects the local contents in terms of materials, equipment and services.

As a result these projects deployed large number of workforce of labour, technicians and supervisors to the tune of about 30,000 at the peak of construction activities.

The IGD Project, in addition to providing sales gas to the consumers in the Emirate, will also provide a permanent link between offshore and on shore facilities of ADNOC Group of companies to provide operational flexibility for Oil and Gas Production.

The Front End Engineering Design (FEED) for the IGD Project was completed last year and during execution of FEED high significance was given to HSE aspects in order to eliminate and adverse impact on the environment and the surrounding community in line with ADNOC HSE Code of Practices.

These Projects will also provide excellent opportunities to UAE Nationals for training and learning new technologies through exposure and interaction with specialists of these engineering companies. This will enable them to enhance their competencies and expertise in the area of project management and also to take on the responsibilities in operation and maintenance.

According to GASCO, the value of this achievement is that it has maintained the best quality and highest standards of environment and safety.

Abu Dhabi Gas Industries Ltd. (GASCO) was established in 1978 in Abu Dhabi to utilise the Emirate’s significant gas resources in its true spirit.

The incorporation and establishment of GASCO as a joint venture between the Abu Dhabi National Oil Company (ADNOC), Shell, Total, and Partex, and the integration of ATHEER (a wholly owned ADNOC Company) in 2001, supported GASCO in realising the vision to be one of the most innovative, respected and caring companies in the gas and hydrocarbon industry.

GASCO’s commitment in meeting the expectations of its stakeholders - shareholders, employees and community, regulatory bodies and non-governmental bodies, was recognised through the renewal of the Joint Venture Agreement originally signed in 1978.

The new Agreement, which is now set to run until September 30, 2028, will allow GASCO to hold the distinction of being one of the major players in the global gas and hydrocarbons market, conducting onshore gas processing and the transportation of gas and liquid products, contributing to the GDP of the UAE in a sustainable and responsible manner.

GASCO has also published a Statement of HSE Commitment and Policy which is based on stringent standards issued by ADNOC (Abu Dhabi National Oil Company). It is a risk-based system and includes a comprehensive range of mandatory requirements to provide a framework for self-regulation and continuous improvement in performance. It is implemented systematically through an HSE Action Planning process.

All GASCO Divisions develop Annual HSE Action plans for implementing various HSE actions. These actions are translated into tasks and targets and are cascaded down the organisation. Progress is regularly reviewed and monitored. An important feature of the Divisional Action Plans is that they contain action items that are SMART (Specific, Measurable, Achievable, Realistic, Time-bound), with each action item being assigned to an individual or team.

The HSE Plan also includes Key Performance Indicators (KPIs), HSE Audits, and HSE Training Plans.

To assure that the HSE MS is effective and functioning, GASCO has an HSE Auditing program in place comprising of different levels of audits. The remedial actions that result from the audits are tracked to final completion through a closeout process. Through this structured approach, the efforts of individuals are directed towards realising the GASCO Vision.

In GASCO, HSE is recognized as a line responsibility and HSE issues are implemented through the involvement of all staff — right from the Chief Executive Officer to the lowest staff. The HSE Division with the Vice President reporting directly to the CEO provides support to the Management Team for the management of HSE.

Each of the Plants / Pipelines Division are supported by HSE Departments headed by a HSE Superintendent who also reports directly to the Plant / Pipelines Vice President.

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