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BANAGAS HERO
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Success stories

Nexus Controls Completes Successful Multi-Vendor Upgrade at BANAGAS



About BANAGAS
BANAGAS logo

 

The Bahrain National Gas Company B.S.C. (BANAGAS) was inaugurated on 17th December 1979 and operates LPG facilities to recover propane, butane, and naphtha from the Bahrain Oil Fields. BANAGAS is a Bahraini company, 75% owned by the Government of the Kingdom of Bahrain represented by Oil and Gas Holding Company “Nogaholding”, 12.5% by Chevron Bahrain and 12.5% by Boubyan Petrochemical Company.

BANAGAS has achieved consistently high levels of production and possesses an internationally-recognized occupational safety record.  BANAGAS is one of the most successful projects implemented for gas processing by the Government of the Kingdom of Bahrain, contributing to the growth and prosperity of the Kingdom and welfare of it's people. Bahrain is an Arab state and island country located in the Arabian Gulf in the Middle East region.

“Nexus Controls delivered success in one of the most complex upgrade projects during one of the most challenging times.  We are so impressed with how they have managed and executed a complex project and delivered it with in schedule maintaining 100% safety records. This has minimized production loss “

 

Introduction

Nexus Controls, a Baker Hughes business, completed a successful control upgrade project with Bahrain National Gas Company (BANAGAS).  The project scope included upgrades for control systems of three gas turbine driven compressors and associated field instrumentation. The scope was subsequently expanded to include additional upgrades involving seven different vendors. The entire multi-vendor BANAGAS project was managed by Nexus Controls.

 

Challenges

BANAGAS needed to upgrade its integrated gas turbine and compressor controls and supporting technologies. The impetus for this upgrade was to proactively sustain BANAGAS' Compressor Stations operations, including consistent throughput levels and an internationally-recognized occupational safety record.

Beyond the controls upgrade, the BANAGAS project was expanded to include seven additional vendors so that all supporting systems were fully upgraded.  The multiple vendor approach introduced additional complexities in terms of project planning, management, and integration.

Further challenges arose because of the global pandemic and travel restrictions. Commissioning of internal and external products during this time added unprecedented challenges to the project execution.

 

Solutions

The integrated turbine and compressor controls contract included the upgrade of three gas turbines from Nexus Controls, while Baker Hughes TPS (Turbomachinery and Process Solutions) worked on the mechanical scope execution for Turbine Module replacement and Turbine starting system upgrade.

The scope expansion encompassing all vendors included:

  • MK-II to Mark VIe Control upgrade on Gas Turbine driven Centrifugal process gas Compressor (ITCC solution), including HMI and Anti surge upgrade
  • Bently Nevada 3500 Vibration Rack Upgrade
  • Moisture Analyzer Upgrade
  • Flow & Process and level Instruments (FT,PT and GWR LTs)
  • Process Gas Valves Upgrade
  • DC System Upgrade (Turbine UPS)
  • Fire & Gas System Upgrade
  • Installation services for above, including full cable replacement

Despite the challenges of the global pandemic and travel restrictions, Nexus Controls was able to mitigate this unplanned challenge and find an alternative solution to execute the project. Enabling remote commissioning was a key element for internal and external products and services, resulting in successful commissioning during the pandemic.

Nexus Controls was appointed to manage the multi-vendor project schedule and ensure a comprehensive and seamless implementation.

 

Benefits

Key Nexus Controls competencies helped to successfully meet BANAGAS’ requirements:

Relationship and Trust. 

BANAGAS entrusted Nexus Controls with both key elements of the project as well as the critical responsibility of project planning across all vendors.  The relationship between BANAGAS and Nexus Controls was a key determinant in positioning Nexus Controls as a trusted partner to successfully handle major project responsibilities.

Complex project planning skills.
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BANAGAS success story graphic

With three planned shutdowns, a global pandemic restricting travel, and seven vendors, orchestration of the BANAGAS project was fraught with challenges.  Nexus Controls went above and beyond to creatively provide a solution to each challenge area and deliver what BANAGAS required – on time, fully safe and on budget.

Expertise, remotely delivered.

Technical expertise was also key to the BANAGAS project execution, including gas turbine / compressor control engineers.  A notable factor of success was Nexus Controls contributions to solving detailed technical challenges to ensure that the proper solution and support was provided. Some of these services were remotely delivered to meet tight shutdown windows while complying with travel restrictions.

HSE Compliance. 

To meet BANAGAS health and safety goals, Nexus Controls complied with the five fundamentals of a perfect HSE day.

 

Result(s)

The sophisticated, multi-dimensional project scope required extensive planning. Nexus Controls established and managed the schedule to ensure that each and every unit would align with TPS’ mechanical scope.

Nexus Controls Services team stretched site management and execution beyond any other experience to meet the customer’s expectations in all three outages. This was accomplished by carefully planning every activity during pre-outage, outage and post-outage stages.

Nexus Controls successfully managed the project execution through to completion and also received a customer appreciation letter from BANAGAS to thank the Nexus Controls team for all their above-and-beyond efforts.

 

About Banagas team

Banagas team, responsible for implementing this project have contributed immensely for successful completion of the project. Banagas team, ably lead by Modernization Project section, was technically competent, quick in decision making and hard working. Banagas management was very co-operative and extremely supportive of the project, which has resulted in mitigating all unforeseen challenges and helped in completing the project successfully, on time.

 

About Nexus Controls

Nexus Controls LLC (formerly GE Energy Controls Solutions) exists as the collective experience and history of multiple companies whose expertise, knowledge, and lineage spans over 150 years.

Our global team of domain experts are in 44 countries on all six continents and have successfully delivered over 11,000 successful projects in the power, oil & gas, and various industrial markets.

 

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