Fieldbus Design and Project Execution for FPSO Projects. Murali Krishnan T and Kaustubh Deshpande Emerson Process Management, Asia Pacific

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1 Fieldbus Design and Project Execution for FPSO Projects Murali Krishnan T and Kaustubh Deshpande Emerson Process Management, Asia Pacific 1

2 FPSO s using Foundation Fieldbus Project Name Owner/ End User Capacity Bpd Date Commissioned Teekay SIRI PetroJarl 15,000 March 2008 PIPA-II Petrobas 30,000 In commissioning Lord of the Sea Greater Plutonio Pemex 200,000 May 2007 BP 240,000 Oct 2007 Enfield Woodside

3 Agenda Typical project organization Implementation Process Modular concept System hardware design, delivery and installation flexibility Software standards for FPSO automation Use of bus technologies 3

4 Proven project execution model Typical project organisation Project Execution Model Stages with defined objectives Key activities Milestones Project Manager Involving specialist in Operational experience Power and Automation Systems How do HSE you do Specialists it? Project support Asset Optimisation Conceptual System and Power Safety and Automation Installation support & Operational engineering detail engineering Systems System Commissioning Support Experienced personnel in Project Management Application knowledge Asset Management Safety and Automation System Instrumentation / Valves Power Systems Fieldbus Technology Global Support Engineering g Installation supervision Commissioning Service Fieldbus Workshops 4

5 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 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 perform FEED Empowered participation in the preparation of tender documents and package procurement to enforce standards and improve data from package units 5

6 Project Execution Design phase Implementation phase FAT Metering Skid FAT Top Sides Site work on yard Site work on Offshore location FDS helps ensure agreement and consistency 6

7 Fieldbus Implementation Process FEED Phase Fieldbus Deployment Assessment Engineering Phase Site Commissioning Phase Commissioning Workshop Final Review Fieldbus Technical Training Fieldbus Application Workshop Design / Simulation Test Segmentation Loop Check & Commissioning 7

8 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 8

9 Engineering Phases FEED Phase Fieldbus Deployment Assessment Engineering Phase Fieldbus Technical Training Fieldbus Application Workshop Design / Segmentation Simulation Test 9

10 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 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 10

11 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 Arrangement of JB, Grounding 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 11

12 Generated by the Project Team Common design philosophy document for all parties Appendix content: Hazardous area concept Components Wiringi Design considerations Control strategy Etc. Functional Design Specification (FDS) 12 12

13 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 l current and voltage 13

14 Fieldbus Segment Design Tool 14

15 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. MIV will then validate for any software constraint and provide Fieldbus Segment Software Analysis to EPC. 15

16 Fieldbus Software Validation Report Macrocycle VCRs and other resources 16 16

17 Site Commissioning Phase FEED Phase Fieldbus Deployment Assessment Engineering Phase Site Commissioning Phase Commissioning Workshop Final Review Fieldbus Technical Training Fieldbus Application Workshop Design / Segmentation Simulation Test Loop Check & Commissioning 17

18 Installation & Pre-commissioning Test Equipment 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 18

19 System modular in Zone 19

20 System modular in Zone Topsides plug&play concept Built & test as stand-alonealone Only electrical connections: power & network M31 M10 M45 20 M60

21 Technical solution for FPSO Cabinets with late IO binding 21

22 Database-Area: M10 - Separation AI module FF PID module FF Pump module Profibus Software Configuration Flexibility Modules in DCS Engineering Database M10 Separation skid M41 - MCC AI PID Pump H1 Profibus Classic & HART I/O Fieldbus I/O 22

23 Use of Bus Technology for FPSO Safety Data Control & Electrical Acquisition Monitoring 23 Digital system architecture that uses the power of field intelligence to improve FPSO performance 23

24 Key success factors: Summary Foundation Fieldbus already used in several FPSO projects Fieldbus architecture fits well with modular construction approach of FPSOs FDS discussion helps to optimize design and save cost Tools and Documentation by Vendor Training at all stages is vital for success 24 24

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