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MOD300 / Freelance DCS evolution to 800xA at Apache gas producer in Egypt

Control system evolution enhances installation and supports future needs, including smart grid utility requirements

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Image courtesy: Apache Corp.

ABB has evolved the installed systems at the Apache facility to meet its changing production and business needs, with system and functionality enhancements that maximize the value of the original ABB system investment.

The largest gas producer in the Western desert

Apache Egypt, a joint-venture between Khalda Petroleum Company and Qarun Petroleum Company, is the largest producer of liquid hydrocarbons and natural gas in the Western desert region and the third largest gas producer in Egypt. It acquired the facility from GUPCO/British Petroleum in 2010.

This plant is one of the main LPG extracting facilities of the Egyptian gas grid, with a daily gross production of 135 million cubic feet or 4,000 barrels/day.

Enhancing the installation beyond HMI expansion

The plant’s original ABB MOD 300 controllers had been running the extraction process since 1992 — a remarkable 20-year history; that was later evolved to ABB’s Freelance AC 800F control technology.

​Further control system evolution project had initially started as a Human ​Machine Interface (HMI) expansion. However, ABB was able to demonstrate that evolving the process controller and operator stations as well could enhance the installation and fully support Apache’s future business needs, including their smart grid utility requirements.

​Operator stations were evolved to ABB’s System 800xA Operations for Freelance platform using AC 800F ​connection software. The number of channels supported by the redundant AC 800F controllers in the new installation grew from 150 to 800.

ABB also conducted customized training on the engineering, configuration and operation of System 800xA for the Khalda Petroleum project team.


Main facts

Industry Oil, gas and petrochemicals
Customer Apache Corp
Country Egypt
Solutions

MOD300 ​/ Freelance DCS evolution to System 800xA


Operator stations were evolved to 800xA Operations for Freelance platform using AC 800F connection software

Integrating process control, asset optimization and power management into one automation platform

System 800xA, with the capability to integrate the plant’s process control, asset optimization and power management into one automation platform, as well as support multi-system integration, also provides the foundation to extend to the control environments of other Apache operations such as its Oil Wells Power House and gas plant in Cairo.

“Our industry expertise and local resources helped this project to be implemented and operated successfully, from design to start-up," says Naji Jreijiri, head of ABB in Egypt.

Mohamed Ismail, project planning general manager for Khalda Petroleum, says:

We appreciate ABB’s cooperation and performance in evolving our DCS system to meet our needs over the years.”

System 800xA provides the foundation to extend to the control environments of other Apache operations such as Oil Wells Power House and gas plant in Cairo.

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