Presenter Name: Sathar Vadhooth Company: Qatar Petroleum

Transcription

1 Presenter Name: Sathar Vadhooth Company: Qatar Petroleum

2 INTRODUCTION PROJECT BACKGROUND FEED AND OPTIONS SELECTION OF FF DESIGN CRITERIA PROJECT EXECUTION ASSET MGMT AND DIAGNOSTICS FF ISSUES IN ME QP BENEFITS Slide 2 of 38

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4 Qatar Petroleum, a National Oil & Gas major owns and operates PS-2 and PS-3 Offshore Oil Production Facilities. QP is responsible for all phases of the Oil & Gas industry in Qatar. QP Covers exploration, drilling, production, storage and transport and sale of crude oil, natural gas liquids, LNG, refined products, petrochemicals and fertilizers. The Corporation is committed to utilize the latest technology. Slide 4 of 38

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8 Project initiated in October FEED in-house completed by QP in April Awarded EPIC to Yokogawa in January Detail Design completed in November Construction started in July Commissioned and handed over in March Slide 8 of 38

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10 PS-3Q CONTROL ROOM Slide 10 of 38

11 PS-3G EXISTING CCR 11 Slide 11 of 38

12 1. TO ARRIVE AT A STRATEGY FOR PS-2/3 CONTROL SYSTEM UPGRADE PROJECT 2. TO FINALIZE THE TECHNOLOGY AND PROJECT SCOPE ANALYSIS IS DONE BASED ON 4 OPTIONS Option-1 Re-use of existing instrument + existing cables Option-2 Re-use of existing instrument + new cables (Conventional DCS) Option-3 All new instrument + new cables (Conventional DCS) Option-4 All new instruments (Fieldbus) Slide 12 of 38

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14 OPTION-1 RE-USE EXISTING INSTRUMENTS + RE-USE EXISTING CABLES Carry out Installation, Cabling and System installation pre-shutdown. Demolish existing Cabinets and Consoles during shutdown. Construct the new facilities and connection. Loop check and Commission. MERITS Existing investment (instruments, cables, cable trays, junction boxes) are retained. DEMERITS Minimum of 4 weeks shutdown of facility is required (cold changeover) A separate marine spread required Scattered cable termination occupies more space and additional junctions Not a good installation Maintenance difficulty Slide 14 of 38

15 OPTION-2 RE-USE EXISTING INSTRUMENTS + INSTALL NEW CABLES Carry out system installation, new instruments and cabling. Lay the cables upto the existing instruments, coil them up and leave. Power on and simulate all loops and check Changeover 5 to 10 loops per day For critical tie-in take a week shutdown MERITS Existing investment (instruments, tubing & fittings) are retained Less shutdown (only a week) Neat and good installation Use of existing LQ accommodation (35 beds). Hence marine spread cost is reduced.. Easy maintenance DEMERITS Additional cable cost and installation cost of QR. 4.0MM Outdated DCS technology NoAsset Management possible (Limited Asset Management) Few old cables will be existing permanently Slide 15 of 38

16 OPTION-3 ALL NEW INSTRUMENTS + ALL NEW CABLES Carry out installation of instruments, cables and system. Loop check and Commission DCS. Changeover loop by loop by demolishing impulse tubing and installing new tubing. MERITS Less shutdown (only a week) Neat and good installation Use of existing LQ accommodation (35 beds). Hence marine spread cost is reduced Easy maintenance Latest equipment, negates some of the maintenance replacements Asset Management possible using HART (but limited) DEMERITS Existing investment (instruments, cables, cable trays, junction box) are not utilized. Additional instrument and installation cost QR. 6.0MM Disruption to platform due to hot works Slide 16 of 38

17 OPTION-4 ALL NEW INSTRUMENTS + ALL NEW CABLES (FIELDBUS) Install all new instruments, cables and system. Commission the system. Loop by loop change impulse tubing. MERITS Less shutdown (only a week) Neat and good installation Use of existing LQ accommodation (35 beds). Hence marine spread cost is reduced Easy maintenance Latest equipment, negates some of the maintenance replacements Asset Management possible using Fieldbus DEMERITS PS-2 Oil Station will be with Conventional instrument and NGL will be Fieldbus (which in our opinion is not a problem) Slide 17 of 38

18 PS-3A PS-3B PS-3C PS-3D PS-3E PS-3G PS-3Q 4 Segments 35 Segments 34 Segments 29 Segments 12 Segments 6 Segments 4 Segments Slide 18 of 38

19 BUL HANINE FIELD PS-3 (Contd.) Field Instrumentation Summary (All Facilities) Description OPTION-1 Re-use Instr Reuse Cable OPTION-2 Re-use Instr New Cables OPTION-3 All New Instr New Cables OPTION-4 FIELDBUS All new Instr New Cables New Instrument required Existing Instrument re-used N/A N/A New Junction Boxes required Existing Junction Boxes reused 50 N/A N/A N/A Single pair Cable required mtrs mtrs mtrs mtrs New Multicore Cable Required 9000 mtrs mtrs mtrs 4500 mtrs Existing Multicore Cable reused mtrs N/A N/A N/A Cost Summary (MM QR) Slide 19 of 38

20 Description OPTION-1 Re-use Instr Reuse Cable OPTION-2 Re-use Instr New Cables OPTION-3 All New Instr New Cables OPTION-4 FIELDBUS All new Instr New Cables Field Instruments Cables System Cost Installation Cost Marine Spread Detail Design FEED Contingency 15% Third party system upgrade cost TOTAL TOTAL BUDGET = QR MM (IN MM QR.) Slide 20 of 38

21 Install FF based DCS for PS-2/3. Shift existing Control Room to new CCR. Integrate ESD, FGS, Telemetry & HVAC with DCS. Replace all existing field instruments (FF Instrs). Install new Closed Circuit Television System. Demolition and Removal of Redundant Equipment. Minimize shutdown requirement. Slide 21 of 38

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23 Reasons for Fieldbus Technology: Existing control technology is 15 to 30 years old. New technology was required for next 20 years. Savings on cabling, cable tray and space. Savings in construction and commissioning. Initial savings in Capital Expenditure (CAPEX). Maintenance and Operational Savings (OPEX). Plant Asset Management. Achieving Enterprise KPI. Slide 23 of 38

24 Growth FF Saturation Conventional A Successful extension strategy could increase sales Launch Maturity Decline Slide 24 of 38

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26 Resulting Design: Over 10,000 I/O FF Devices 1024 Segments 225 DCS Non FF I/O 1800 Avg FF Dev per Segment 4.7 DESIGN CRITERIA High Power trunk with barriers at Field. One sec. max macrocycle time. Eight devices max in segments. Three final control elements max in a segment. Critical loops shall be assigned to dedicated segments. Parallel equipment I/O shall not reside in same segment. Multivariable transmitters for flow totalizer with compensation application. Slide 26 of 38

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29 Exist. LER/Comp. Room TX, L/ Panel / S.S. LER Ex-Panel Comp Room New DCS Cab & M/C New DCS CCR New DCS Slide 29 of 38

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33 NE107 defines 4 status signal or level for diagnosis: The classification and association of a diagnosis event to one of the 4 level of diagnosis must be configurable by the user. Slide 33 of 38

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35 1. Ability to display and interact with the Maintenance and Diagnostic Software package of ANY FF Instrument from ANY Manufacture via ANY Host using standard, open protocols. 2. Expand Interoperability Test for hosts. 3. FF Training center in the Middle East. 4. Engineering Contractor and package Unit Support of FF. 5. Availability of FF expertise with Vendors in Middle East is low. Slide 35 of 38

36 Provide solutions for TCO reduction in plant lifecycle Planning Construction Operation Maintenance Improvement Plant Construction Phase Reduced Hardware Cost - I/O modules, Field Devices - Reduction of Wiring - Reduction of control room space (No Marshaling) Reduced Project Lead Time - Design & Engineering Tools - Design Guidelines and Documents 9% reduction of Installation cost (By ARC) Plant Operation Phase Reduced Operating Cost - Minimum Manning - Minimum Cost for Upgrading Reduced Maintenance Cost - Condition based, Predictive Maintenance - Tool based Maintenance - Automatic Maintenance Reduced Safety Cost - Remote Maintenance - Higher plant availability 20% reduction of Operation cost (By ARC) Slide 36 of 38

37 CABLING TERMINATIONS PANEL SPACE COMMISSIONING OVERALL COST SAVING BENEFITS 25% Reduction 35% Reduction 50% Savings 50% Savings 21% Savings Slide 37 of 38

38 Contact No address: Slide 38 of 38