Doha, Qatar – Exploration engineers discovered ever natural gas off the Northeast handlecoast of...

“By working with Invensys, RasGas is setting the pace for the LNG industry globally, supplying more efficient and more environmentally friendly energy for export to the world.”

RasGas Pumps Up Production

Goals• Implementcost-savingmeasurestoextend

businessefficiencies• Expandproductionwhilemaximizingexisting

technologies

Challenges• Communicationfromon-shorecontrolroomto

off-shorewellis130kmaway• Multipleoperatingplatformsandhardware

versions

Solutions and Products• FoxboroDistributedControlSystem-I/ASeries®• TriconexSafetyInstrumentedSystems

Results• World’slargestLNGsupplierwithexpectedtotal

productionof77milliontonsperyear• World’slongestsafetysystempeer-to-peer

networkallowstheonshoreLNGsystemtoshut-downtheremoteoffshorewellheadsfromadistanceof130km

• Providedlowestrisklevelandwiththehighestlifecyclevalue

INDUSTRY:UPSTREAMOIL&GAS

RasGaswww.rasgas.com

Doha, Qatar–ExplorationengineersdiscoverednaturalgasofftheNortheastcoastofQatarin1971.Atthetime,themagnitudeofthediscoverycouldnothavebeenimagined.Sincethen,theNorthField(asitisnowknown)hasbeenconfirmedasthelargest,non-associatednaturalgasfieldintheworld.Withmorethan900trillionstandardcubicfeetofreserves,NorthFieldrepresents10percentoftheworld’snaturalgasreserves.

Drillingforgasisonlypartofthestory.ThoughQatar’snaturalgasislocatedinthisgiant,offshorefield,itstillneedstobesuperchilledasliquefiednaturalgas(LNG)forexport.Thissuperchillingoperationtakesplaceonshore130kmawayinagasprocessingplantcalleda“train”.RasGas,oneoftheworld’spremierintegratedLNGenterprises,hasseventrains,includingtwooftheworld’slargest.

TocapitalizeonthegasdiscoveryinNorthField,RasGasneededtodevelopnew,world-classfacilitiesfortheextraction,storage,processingandexportofLNG.Long-termagreementstosupplycustomersaroundtheglobe,includingKorea,India,Italy,Spain,Taiwan,BelgiumandtheUnitedStateshavepositionedRasGastobecomethelargestsupplierofLNGworldwide.

RasGasneededacompanytoprovidetimelydesigninformationintheengineeringphaseandaconsistentdesignthroughoutprojectdevelopment,despitethesheersizeoftheproject.Inaddition,allworkwasbeinghandledfromacombinationofdifferentengineeringlocations.

Theclearchoicewastheproducts,servicesandsolutionsprovidedbyInvensysOperationsManagement.Invensysoffersthemostholisticandcost-effectivewaytooptimizeoperationperformanceandoverallprofitability.Invensyshelpsimprovetheperformanceofkeyresources(people,equipment,energyandmaterials)inrealtime—withdramatic,measurableresults—usingacollaborativeandopenapproach.

OneofthemainreasonsInvensyswasselectedwastheirstrongprojectexecutioncapabilitywithdeepknowledgeofLNGapplicationsandtheexistinginstallationatRasGas.Operatinginan

everchangingenvironment,Invensys’abilitytohandlelatedesigninformationfrompackagevendorshelpedminimizeimpacttotheprojectschedule.

RigorousFactoryAcceptanceTesting(FAT)helpedtointegrateFoxboroI/ADistributedControlSystem,TriconexCriticalandSafetySystemsandotherapplicationsystems–alltestedwithinanintegratedenvironment.Withitswealthofexperience,Invensyswasabletoidentifycriticaltie-insearlyintheproject,whichhelpedtomitigatetherisksassociatedwithworkinginaliveplant.

Duetothelargescaleoftheprojectandextendedtestingperiod,theInvensysteamhadbeverydetailedintheFAT,takingintoconsiderationmanydiverseconcerns,includingshipmentconstraints.Invensys’world-classprocessautomationbroughttechnologicallyadvancedattributestoensureaseamlessimplementationinthislargescaleLNGproject.

Bigger and Better

RasGas’hugeinvestmentintoLNGplacesQatarontheworld-mapasaleadingglobalnaturalgasproducer.In1999,thefirstyearofproduction,RasGasproduced6.6milliontonsperannum(MTA)withitsfirst2trains.Asmoretrainscameonline,productionincreasedtoalevelwhere

industryexpertsestimatethatsoonQatarwillsupply30%oftheworld’sLNG.WithTrains6and7online,eachproducing7.8MTA,thesetwoprojectsrepresentabigsteptowardsQatarbecomingtheworld’slargestsupplierofLNGwithexpectedtotalproductionof77MTA.

The Invensys Solution

Theexistingcontrolsystemhadmultipleoperatingplatformsandhardwareversions.Invensyshadtostrikeadelicatebalancebetweenexistingandnewtechnology.Systemlimitsondatatrafficintheexistingsystemcoupledwiththenumberofcontrolstationsalsoimpactedtheadditionofnewstationsandapplications.

Toachievethesegoals,Invensysdeliveredthebest-in-classtechnologiesincontrolandsafetysystems,providingexpertiseinserialdatacommunications(HART,Modbus,ProfiBus,OPCandHighSpeedEthernet),insinglesystemintegration,providingmissioncriticalinformationandcontrolfortheoperationoftheLNGPlant.

Becausetheoffshorewellheadsrequirereal-timecommunicationwiththeonshoreoperations,Invensysdeliveredtheworld’slongestsafetysystempeer-to-peernetwork,whichallowstheonshoreLNGsystemtoshut-downtheremoteoffshorewellheadsfromadistanceof130km.

Invensys’uniquesolutionallowsforinteroperabilityonasolidintegratedplatform,byutilizingFoxboroI/ASeriesConfigurationComponent(IACC)EngineeringSuite,imbeddingFieldDeviceTool(FDT)technologyandFieldDeviceManagement(FDM)intooneconsistentsingleengineeringenvironment.AllFieldBusstandardsinteroperatewithinthesystemutilizingonecoherentprojectdatabaseforthesystemandfielddevices.

TheFoxboroI/ASeriesistheworld’sfirstOpenControlSystem(OCS),whichallowsuserstocontinuouslydeploymoreadvancedcontrolstrategies,applicationandengineeringpackages.OCSallowsfortheabilitytomigratefromoldertechnologytothenewesttechnologyandprovidesaguaranteeofsystemsandhardwarebeingcontinuouslycurrent.

The Energy to Succeed

Invensysprovidedarobustandsustainablesolutionallowingforanalysis,measurementsandimprovementsinLNGplantperformance.AdvanceAlarmPackage,LoopPerformanceandInstrumentAssetManagementwereprovidedforTrain6&7.ThesolutionsuitewasalsoenhancedwithcontrolsystemsforPre-treatment,ProductionandThroughput,RefrigerantCompositionandLoad,MainHeatExchanger,LiquefiedPetroleumGas(LPG)recoveryandFractionationSystemQuality.

InvensysbroughtuniqueattributestotheRasGasoperation,whichensuredsuccessatthelowestrisklevelandwiththehighestlifecyclevalue.Invensysshowcasedextensiveandlong-termexperienceinQatar,andastrongtrackrecordindesignandimplementation.TheexpansionandretrofitofRasGas’LNGplantprocessautomationsystemsincorporatedbothlegacyandnewsystemsintooneintegratedsystem.

Asunanticipatedsituationsarose,Invensysprovedtobeveryflexibleandadaptableinhandlinglatechangesindesigndatawithoutimpactingprojectdeliverydates.ControlSystemswereengineered,installedandpre-commissionedtoachieverecord-breakingcompletiondates.

Thesefactorsresultedinthedeliveryofthelowestriskcontrolsystemandadvancedapplicationsystem,designedandimplementedbyengineerswhoweretechnicalexpertsandunderstoodthebusinesscontextofRasGas’market.

WhiletheInvensysteamworkedonthelivesystem,theyconsideredtheneedfortie-inpackageengineeringtofollowstrictqualitycontrolprocedures,makingsurethesystempassedthroughastringentreviewprocessandgainedapprovalfromRasGas.Invensysdidevenmorebyformulatingarisksandmitigationplan.Thiswasexecutedseamlesslywhilefacedwithscheduleconstraintsinshiploadingandplannedshutdownactivities.

With40%ofworldwideLNGproductioncontrolledbyInvensysandtheirbest-in-classLNGexecutionteam,RasGashaschosenaviablepartnerandsystemintegratorthathasensuredcosteffectivenessatthelowestrisk.Technologyisakeyenablerinachievingsuchascaleofproduction.ThesizeandcostefficienciesofeachtrainequippedwithInvensystechnologywilleventuallycontributetolowercostsofproducingLNG.

Withsuchexperience,InvensysismorethanqualifiedtoserviceRasGasfortheentire25-yearlifecycle.ByworkingwithInvensys,RasGasissettingthepacefortheLNGindustryglobally,supplyingmoreefficientandmoreenvironmentallyfriendlyenergyforexporttotheworld.

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Rev.06/10