The benefits of modern Integrated Control and Safety Systems architectures for FPSO facilities. P. Troianiello - Fores Engineering Rosetti Marino Group A. Gariboldi - Siemens Industry Sector IA/DT
Topics FPSO - Definition FPSO - Features Off-Shore Project today s core requirements FPSO customer s trend requirements A real application of ICSS Where we can have benefits Conclusions
FPSO Definition A Floating Production, Storage and Offloading (FPSO) unit is a floating vessel used by the Offshore Oil& Gas Industry for the processing of hydrocarbons and for storage of oil. An FPSO vessel is designed to receive hydrocarbons produced from nearby platform or subsea template, process them, and store oil until it can be offloaded onto a tanker or, less frequently, transported through a pipeline. (by Wikipedia)
FPSO - Features FPSOs can be a conversion of an oil tanker or can be a vessel built specially for the application. In case of conversion of an oil tanker the following steps are carried out: Hull refurbishment Topside (process area) implementation Turret Implementation 300/400 meters Process Plants TOPSIDE VESSEL HULL & TANKS TURRET Wheel Room, Engine Room, Accomodation Umbilical Cords and Drillling
Today s core requirements >>> Reduction of time to «first oil» = earlier production = earlier ROI Off-Shore Project Core requirements: How to make engineering more cost-favorable with improved quality? How to accelerate time to electrical-instrumental installation completion? How to accelerate time to production with faster commissionig & start-up? How to reduce complexity and interfaces during operational and maintenance activities? Reduced costs Piping, Vessels & Structure Rotating Equip Enhanced quality Automation 2-6% 15-30% Minimized time Bulks Percent age of Project Spent Suppliers offering a truly integrated offering of process and safety are saving end users substantial project costs in engineering and lifecycle expense. Source: ARC Impact on Operations Over Time
FPSO Customer Requirements Actual Trend: Overall costs optimization Don t compromise quality Don t compromise safety Time to commissioning reduction Use of modern technologies Very integrated, that is from the same manufacturer Integrated Control & Safety System PCS ECS F&G/ESD Topside F&G Vessel Reduction of process hardware links and junction boxes by using remote I/O boxes suitable for field installations F&G Integrity Level SIL 2 ESD Integrity Level SIL 3 Accomodation Fire Detection based on addressable system Removal of hardwired links between the systems by the replacement with «safety buses» and «certified protocols».
Fire ext.. acktivated Fire vent. activ. Fire Brig. recvd. Power Prewarning Early warning Fault System fault Function disabled Test More Alarms Silence buzzer Silence sounders Reset 1 4 7 C? 2 5 8 0 3 6 9 Self Verify ICCS Overall Architecture Central Control Room Wheel Room Engine Room F&G Operator WS & Video wall Operator Workstations SOER F&G Operator WS F&G Operator WS REDUNDANT RING TERMINAL BUS ETHERNET Engineering Workstation PCS/ECS Redundant Server ESD/F&G Redundant Server HISTORIAN Redundant Server Central clock REDUNDANT OPTICAL RING TERMINAL BUS ETHERNET Safe Data Link PCS ECS F&G/ESD Topside F&G Vessel REDUNDANT PROFIBUS-DP REDUNDANT PROFIBUS-DP REDUNDANT PROFIBUS-DP PROFISAFE SIL 2 or 3 ALARM Local Equipment Room OR Central Equipment Room SIL 2 or 3 Addressable Loops SIL 2 or 3 OPTICAL REDUNDANT PROFIBUS DP RIO 1 LCP RIO 2 LCP Field Local Control Panels RIO N LCP Eex-d, Eex-i, Eex-p Accomodation
ALARM Fire ext.. acktivated Fire vent. a ctiv. Fire Brig. recvd. Power Prewarning Early warning Fault System fault Function disabled T est More Alarms Silence buzzer Silence sounders Reset 1 4 7 C? 2 5 8 0 3 6 9 Se lf Ve rify ICCS Overall Architecture Wheel Room Central Control Room About 250 mt Process Field Junction Boxes LER Engine Room F&G/ESD ECS PCS F&G About 120 mt Accomodation About 300/400 meters
Real application - Control REDUNDANT RING TERMINAL BUS ETHERNET 100Mbits/s AVG DIST = 25 mt GT1 GT2 MV Switchboard LV Switchboard 1 LV Switchboard 2 Electrical Cabinet s in Safe Room PCS Panel ECS Panel 2000 I/O 1000 I/O MCC Switchboard AVG DIST =150 mt L.Q. Switchboard Emergency MCC RIO LCP Module 1 RIO LCP Module 2 RIO LCP Module 3 RIO LCP Module 4 RIO LCP Module 5 RIO LCP Module 6 Process Field Junction Boxes (Eex-d, Eex-i, Eex-p or in Safe Area according Hazardous Area) RIO LCP Module 7 RIO LCP Module 8 RIO LCP Module 9 RIO LCP Module 10 RIO LCP Module 11 RIO LCP Module 12
Fire ext.. acktivated Fire vent. activ. Fire Brig. recvd. More Alarms Power Prewarning Early warning Fault System fault Function disabled Test Silence buzzer Silence sounders Reset 1 4 7 C? 2 5 8 0 3 6 9 Self Verify Real application - Safety PROFISAFE SIL3 F&G/ESD Topside (located in LER) ESD SYSTEM SIL3 ESD SYSTEM SIL2 PROFISAFE DATA EXCHANGE SIL 3 on Ethernet REDUNDANT I/O MODULE (Q.ty Nr. 2+2 AI Module; 1+1 DI Module; 1+1DO Module) SINGLE I/O DIST =100 mt F&G SYSTEM SIL2 AK4 800 SW Signals instead of 800 I/O SINGLE I/O PROFISAFE SIL 2 VESSEL ADRESSABLE F&G SIL2 ALARM 300 SW Signals (Shutdown causes) instead of 300 I/O VESSEL F&G SYSTEM SIL2 F&G Vessel (located in CCR) 2000 I/Os 700 I/Os SINGLE I/O ADRESSABLE LOOPS SIL 2 600 Devices
Real application Cabling saving Cable saving (12 pairs shielded armoured), related cable trays, junction boxes, bulk materials and installations activities. PCS Panel PCS remote rack I/O ECS Panel ECS remote rack I/O F&G Topside F&G remote rack I/O F&G Topside F&G vessel F&G Vessel Addressable Panel Field Loops Addressable Panel Remember also a simpler field engineering!
Real application New safety sw tools Today technologies offers safety software tools able to save costs during the Safety Lifecycle from the engineering to operation and maintenance phases. Risk Analysis and Protection Layer Design Sub-clause 8 Manageme nt of Functional Safety and Functional Safety Assessment Safety Lifecycle Structure and Planning Allocation of Safety Functions to Safety Instrumented Systems or other means of risk reduction Sub-clause 9 Safety Requirements Specification for the Safety Instrumented System Sub-clause 10 Verificatio n Design and Development of Safety Instrumented System Sub-clause 11 Design and Development of other means of Risk Reduction Sub-clause 9 Installation, Commissioning and Validation Sub-clause 14 Sub-clause 5 Subclause 6.2 Operation and Maintenance Sub-clause 15 Modification Sub-clause 15.4 Subclause 7, 12.7 Decommissioning Sub-clause 16 Cause & Effects Engineering, Operations and Maintenance Tool - Eliminates translation errors by automatically generating the logics - Automatically generates HMI faceplate to visualize matrix - Interface for maintenance overrides and I/O simulation during FAT or SAT - Automatically generates change the documentation (IEC 61511) and the Events Log
Where we can have benefits? ICSS FEATURES Integrated Control & Safety System from the same manufacter Distributed Remote I/Os on Profibus or High Speed Ethernet Certified Bus with protocol according IEC61508/61511 Addressable Fire Control Panel according IEC61508/61511 vs. vs. vs. vs. PROJECT LIFE PHASE Multiple manufactures Traditional point-to point hardwired links Traditional safety hardwired link Not Adressable Engineering Yes Yes Yes Yes Cabling Material Yes Yes Yes Installation Yes Yes Yes Commissioning Yes Yes Yes Yes Operation Yes Maintenance Yes Yes Yes Yes
Conclusions New features of Integrated Control & Safety System combined with certified safety buses and addressable F&G systems Architecture Semplicity Technical Innovation Overall Costs Interfaces But the most consistent financial benefit, due to an earlier installation and commissioning, is the time reduction of an earlier First Oil. This economical value could be definitely ten times greater than the saving obtained during the project, depending on the expected daily plant production. Therefore, nowadays, EPC contractors or End-User have new opportunities to optimize the costs of the overall plant lifecycle, taking advantage of the new technologies offered by Control & Safety systems, even though the more difficult barrier to overcome are the old cultural heritages that often we could have, despite we live in the age of the networks.
Thank you! Fores Engineering is an Italian company established in 1992, part of the Rosetti Marino Group, specialized in the Project Management, Engineering, Procurement, Integration, Construction and Commissioning of systems for the Oil & Gas both upstream and downstream, in the field of Offshore platforms and Onshore plants, Petrochemical, Chemical and Power plant fields. Its main products are Control & Safety Systems, Telecommunication & Security Systems, Skid Mounted Package Units, Wellhead Control Panels, Process Analyzer Systems, Equipped Shelters. Siemens is a global company operating in the sectors of industry, energy and healthcare, providing also solutions for the infrastructure of cities and metropolitan areas. Distinguishable from over 165 years of innovation, quality, reliability, technological excellence, Siemens is the leading global provider of environmentally sustainable technologies, Industry Sector The Siemens Industry Sector is a leading global provider of innovative products and solutions to customers in the industry. Large market experience-based services and software for industrial processes are some of the main levers that we use to increase productivity, efficiency and flexibility of our customers.