Project Overview
ADNOC Gas Processing operates one of the most extensive sales gas pipeline networks in the Middle East, approximately 3.000 km of infrastructure stretching across Abu Dhabi, supplying gas to consumers at precisely controlled pressures and flow rates.
As part of a major upgrade program at the Habshan Gas Compressor Plant (HGCP), the project required a state-of-the-art High Integrity Pressure Protection System (HIPPS) to safeguard critical process equipment and personnel.
The result is what has been recognized as the largest HIPPS ever built, integrated by Orion HIPPS and recently presented in Dubai.
Indra is proud to have contributed a core component of this landmark installation.
The Challenge
A HIPPS operates as a Safety Instrumented System, designed to prevent overpressure events from reaching downstream equipment by triggering automatic isolation before dangerous conditions develop.
In this application, the demands were exceptionally stringent: high-pressure sour service duty, a wide operating temperature range, and a harsh field environment characterized by humidity, salinity, and sandstorms, all while meeting SIL 4 integrity requirements in accordance with IEC 61508 and IEC 61511.
The instrument isolation architecture required a 2oo3 voting logic (two-out-of-three) on pressure transmitters, demanding a manifold solution capable of supporting three transmitters in continuous operation while maintaining full process isolation capability and material compliance for sour service conditions.
Indra's Solution
Indra supplied a purpose-engineered Double Block & Bleed interlocking manifold configured specifically for 2oo3 applications.
Rather than a conventional multi-component assembly with multiple potential leak points, Indra's integrated design consolidates isolation, venting, and position feedback into a single compact unit.
Key features include:
- Double Block & Bleed needle valve configuration ensuring complete process isolation and safe venting during maintenance
- Intrinsically safe proximity switches (ATEX/IECEx/ECAS certified) integrated directly into the manifold body, providing position feedback to the safety logic solver
- High-pressure flanged process connection with all wetted components in SS 316/316L, fully compliant with NACE MR 01-75 / ISO 15156 for sour service duty
- Weatherproof stainless steel enclosure (IP66) with thermal insulation, safety viewer window, and dedicated Ex ia junction boxes — engineered to protect instrumentation against the demanding Abu Dhabi field environment
- SIL 4 certified assembly in accordance with IEC 61508 and IEC 61511
The complete assembly underwent full factory acceptance testing at Indra's facility in Magenta, Italy, including functional verification of the interlocking mechanism, hydrostatic pressure testing, and positive material identification on all wetted components.
Outcome
Indra's Interlocking Manifold delivered a compact, fully integrated solution that simplified field installation, reduced potential leak paths compared to conventional assemblies, and provided the certified safety performance required for one of the most demanding oil and gas environments in the world.
Manufactured entirely in Italy, the assembly reflects Indra's commitment to engineering precision and project reliability at the highest level.
Being present in Dubai at the unveiling of this record-breaking installation is a point of great pride for the entire Indra team, and a testament to what is achievable when the right partners collaborate around shared standards of excellence.
