Fieldbus Design and Project Execution for FPSO Projects
Murali Krishnan T and Kaustubh Deshpande K t bh D h d Emerson Process Management, Asia Pacific
FPSOs using Foundation Fieldbus
Project Name Teekay SIRI PIPA-II Lord of the Sea Greater Plutonio Enfield Owner/ End User PetroJarl Petrobas Pemex BP Woodside Capacity Bpd 15,000 30,000 200,000 240,000 Date Commissioned March 2008 In commissioning May 2007 Oct 2007 2007
Singapore FPSO Seminar - 21 August 2009
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Agenda
Typical project organization Implementation Process Modular concept System hardware design, delivery and installation y g , y flexibility Software standards for FPSO automation Use of bus technologies
Singapore FPSO Seminar - 21 August 2009
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Proven project execution model Typical project organisation
Project Execution Model Stages with defined objectives Key activities Milestones
HSE Project Manager
Involving specialist in Operational experience Power and Automation Systems
Specialists
How do you do it? y
Project P j t support t Asset Optimisation Conceptual p engineering System and y detail engineering Power Systems Safety and Automation Installation support & y pp System Commissioning Operational p Support
Experienced personnel in Project Management Application knowledge Asset Management Safety and Automation System Instrumentation / Valves Power Systems Fieldbus Technology
Global Support g g Engineering Installation supervision Commissioning Service Fieldbus Workshops
Singapore FPSO Seminar - 21 August 2009
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Project Execution FEED Phase
Integrated Engineering Team during FEED, follow-up engineering and site integration coordination
( Customer / Contractor / Suppliers / End-user ) Customer/End-User/Contractor experts availability Co-design Co design on solutions Prepare and train customer organization and yard-teams for utilization of new designs/techniques and maximize the yield Prepare and distribute project design specifications and f perform FEED Empowered participation in the preparation of tender documents and package procurement to enforce standards and improve data from package units
Singapore FPSO Seminar - 21 August 2009
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Project Execution
Design phase Implementation phase FAT Metering Skid FAT Top Sides Site work on yard Site work on Offshore location
FDS helps S ensure agreement and consistency
Singapore FPSO Seminar - 21 August 2009
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Fieldbus Implementation Process
FEED Phase
Fieldbus Deployment Assessment
Site Commissioning Phase
Commissioning Workshop
Engineering Phase
Fieldbus Technical Training
Final Review Loop Check & Commissioning
Fieldbus Application Workshop Simulation Test
Design / Segmentation
Singapore FPSO Seminar - 21 August 2009
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FEED Phase
FEED Phase
Fieldbus Deployment Assessment
Example of Physical Design: Hazardous Area Easier live maintenance: -Exi - ExnL What device and component hazardous area certification is required? -FISCO devices for FNICO -Entity Exi devices for Entity ExnL
Singapore FPSO Seminar - 21 August 2009
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Engineering Phases
FEED Phase
Fieldbus Deployment Assessment
Engineering Phase
Fieldbus Technical Training
Fieldbus e dbus Application Workshop Simulation Test
Design / Segmentation
Singapore FPSO Seminar - 21 August 2009
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Training for Success
Training is a critical success factor for any projects For most projects the customer, EPC, and sub-contractors have not undergone extensive Foundation fieldbus training Standard training must be customized to the unique design and requirements of each project
Day 1 1) Foundation Fieldbus Technical Overview 2) Project Fieldbus Component 3) Segment Design ) g g 4) Fieldbus Installation 5) Field-Check and Troubleshooting Day 2 6) Transmitter - Fieldbus functionality 7) Valve Positioner - Fieldbus functionality 8) Fieldbus Systems Setup (Hands-on) 9) Roundup : Questions and Answers
Singapore FPSO Seminar - 21 August 2009
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Fieldbus Application Workshop
EPC defines philosophy (rules) by which Fieldbus devices are allocated to the bus to achieve desired control availability
Workshop topics for discussion: Control Loop / Valve Criticality Ranking Application Scope of Foundation Fieldbus Cable Selection A Arrangement of JB, Grounding t f JB G di Redundant Philosophy Macro-cycle philosophy Function Block Requirement Controller Location (CIC/CIF) Zone Application
Consists of: - Definition of control loop criticality level - Restrictions for allocation for control criticality level - Analysis and ranking of control loops/valves Impacts: - Number of devices per bus - Number of loops per bus
Singapore FPSO Seminar - 21 August 2009
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Functional Design Specification (FDS) Generated by the Project Team Common design philosophy document for all parties Appendix content: Hazardous area concept Components Wi i Wiring Design considerations Control strategy gy Etc.
Singapore FPSO Seminar - 21 August 2009
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Fieldbus Implementation Methodology
(EPC)
EPC will load the segment based on process plot plan and results from Segment Design Tool, risk assessment, process criticality and equipment unit.
Segment Allocation = assigning devices to bus Segment Loading = block and communication timing Segment Design = calculate current and voltage S tD i l l t t d lt
Singapore FPSO Seminar - 21 August 2009
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Fieldbus Segment Design Tool
Singapore FPSO Seminar - 21 August 2009
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Fieldbus Implementation Methodology
EPC will load the segment based on process plot plan and results from Segment Design Tool risk assessment process criticality and plant unit Tool, assessment, unit. MIV will then validate for any software constraint and provide Fieldbus Segment Software Analysis to EPC.
Singapore FPSO Seminar - 21 August 2009
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Fieldbus Software Validation p Report
Macrocycle VCRs and other resources
Singapore FPSO Seminar - 21 August 2009
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Site Commissioning Phase
FEED Phase
Fieldbus Deployment Assessment
Site Commissioning Phase
Commissioning p Workshop
Engineering Phase
Fieldbus Technical Training
Final Review Loop Check & Commissioning
Fieldbus e dbus Application Workshop Simulation Test
Design / Segmentation
Singapore FPSO Seminar - 21 August 2009
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Installation & Pre-commissioning Test Equipment q p
Establish procedure and checklist Hands-on training Installation test tools are made available in required quantity so as to not delay project Fieldbus power and signal simulator Fieldbus tester Oscilloscope R and C meter Pre-commissioning test tools are made available Fieldbus tester Handheld field communicator
Singapore FPSO Seminar - 21 August 2009
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System modular in Zone
Singapore FPSO Seminar - 21 August 2009
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System modular in Zone
Topsides plug&play concept Built & test as stand alone stand-alone Only electrical connections: power & network
M31 M10
M45
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M60
Technical solution for FPSO Cabinets with late IO binding g
Singapore FPSO Seminar - 21 August 2009
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Software Configuration Flexibility
Database-Area: M10 - Separation AI module FF PID module FF Pump module Profibus
Modules in DCS Engineering Database
M10 Separation skid
AI PID
M41 - MCC
Pump
H1
Profibus
Classic & HART I/O
Fieldbus I/O
Singapore FPSO Seminar - 21 August 2009
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Use of Bus Technology for FPSO
Safety
Data Acquisition
Control & Monitoring
Electrical
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Digital system architecture that uses the power of field intelligence to improve FPSO performance
Singapore FPSO Seminar - 21 August 2009
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Summary
Key success factors:
F Foundation Fieldbus already used in several FPSO d ti Fi ldb l d di l projects Fieldbus architecture fits well with modular construction approach of FPSOs FDS discussion helps to optimize design and save p p g cost Tools and Documentation by Vendor Training at all stages is vital for success 24
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