FF Design and project execution FPSO.ppt - · PDF filePIPA-II Petrobas 30,000 In commissioning...

Fieldbus Design and Project Execution for FPSO Projects

Murali Krishnan Tand

K t bh D h dKaustubh DeshpandeEmerson Process Management, Asia Pacific

1

FPSO’s using Foundation Fieldbus

ProjectName

Owner/End User

CapacityBpd

Date Commissioned

Teekay SIRI PetroJarl 15,000 March 2008

PIPA-II Petrobas 30,000 In commissioning

Lord of the Sea

Pemex 200,000 May 2007

Greater Plutonio

BP 240,000 Oct 2007

Enfield Woodside 2007Enfield Woodside 2007

2Singapore FPSO Seminar - 21 August 2009

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 technologiesUse of bus technologies


Proven project execution modelTypical project organisationTypical project organisation

Project Manager

Involving specialist in• Operational experience • Power and Automation Systems

Project Execution Model• Stages with defined objectives

• Key activities

How do you do it?Specialists HSE

• Key activities• Milestones

P j t t Asset y

Conceptual System and Power Safety and Automation Installation support & Operational

Project support Optimisation

pengineering

ydetail engineering Systems

ySystem

ppCommissioning

pSupport

Experienced personnel in • Project Management• Application knowledge

Asset Management

• Global Support• Engineering• Asset Management

• Safety and Automation System• Instrumentation / Valves• Power Systems• Fieldbus Technology

g g• Installation supervision• Commissioning• Service• Fieldbus Workshops


Project ExecutionFEED Phase

Integrated Engineering Team during FEED, follow-up engineering and site integration coordinationengineering and site integration coordination

• ( Customer / Contractor / Suppliers / End-user )• Customer/End-User/Contractor experts availability

Co design on solutions• Co-design on solutions• Prepare and train customer organization and yard-teams for

utilization of new designs/techniques and maximize the yieldf• 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


Project Execution

• Design phase• Implementation phase• FAT – Metering Skid• FAT – Top Sides• Site work on yard• Site work on yard• Site work on Offshore location

SFDS helps ensure agreement and


and consistency

Fieldbus Implementation Process

Fieldbus

FEED Phase Site Commissioning Phase

FieldbusDeployment Assessment

Fieldbus

Engineering Phase

Commissioning Workshop

Final Review

Loop Check &FieldbusTechnical Training Fieldbus

ApplicationWorkshop Design /

Segmentation

Loop Check & Commissioning

SegmentationSimulation

Test


FEED Phase


FEED PhaseExample of Physical Design: Hazardous Area•Easier live maintenance:-ExiAssessment- ExnL•What device and component hazardous area certification is required?-FISCO devices for FNICO-Entity Exi devices for Entity ExnL


Engineering Phases


FEED Phase

Assessment

FieldbusTechnical Training Fieldbus

Engineering Phase

Training e dbusApplicationWorkshop Design /


Test


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 1Day 11) Foundation Fieldbus Technical Overview 2) Project Fieldbus Component 3) Segment Design) g g4) Fieldbus Installation 5) Field-Check and Troubleshooting

Day 2Day 26) Transmitter - Fieldbus functionality 7) Valve Positioner - Fieldbus functionality 8) Fieldbus Systems Setup (Hands-on)


9) Roundup : Questions and Answers

Fieldbus Application Workshop

EPC defines philosophy (rules) by which Fieldbus devices are allocated to the bus to

Workshop topics for discussion:

• Control Loop / Valve Criticality Ranking

Fieldbus devices are allocated to the bus to achieve desired control availability

Consists of:- Definition of control loop criticality level

• Control Loop / Valve Criticality Ranking

• Application Scope of Foundation Fieldbus

• Cable Selection

A t f JB G di

- Restrictions for allocation for control criticality level- Analysis and ranking of control loops/valves

• Arrangement of JB, Grounding

• Redundant Philosophy

• Macro-cycle philosophy

Impacts:- Number of devices per bus- Number of loops per bus

• Function Block Requirement

• Controller Location (CIC/CIF)

• Zone Application


Functional Design Specification (FDS)

• Generated by the Project Team

• Common design philosophy document for all parties

• Appendix content:• Appendix content:– Hazardous area concept– Components

Wi i– Wiring– Design considerations– Control strategygy– Etc.

12Singapore FPSO Seminar - 21 August 2009 12

Fieldbus Implementation Methodology

(EPC)(EPC)

• EPC will load the segment based on process plot plan and results from Segment Design Tool, risk assessment, process criticality and equipmentSegment Design Tool, risk assessment, process criticality and equipment unit.

Segment Allocation = assigning devices to busSegment Loading = block and communication timingS t D i l l t t d lt


Segment Design = calculate current and voltage

Fieldbus Segment Design Tool


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 unitSegment 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.


Fieldbus Software Validation• Reportp

– Macrocycle– VCRs and other resources

16Singapore FPSO Seminar - 21 August 2009 16

Site Commissioning Phase


FEED Phase Site Commissioning Phase

Commissioning WorkshopAssessment

FieldbusTechnical Training Fieldbus

Engineering Phasep

Final Review

Loop Check & Commissioning

Training e dbusApplicationWorkshop Design /


Test


Installation & Pre-commissioningTest Equipmentq 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 simulatorFieldbus power and signal simulator– Fieldbus tester– Oscilloscope

R and C meter– R and C meter• Pre-commissioning test tools are made available

– Fieldbus tester– Handheld field communicator


SSystem modular in Zone


System modular in Zone

Topsides plug&play conceptBuilt & test as stand aloneBuilt & test as stand-aloneOnly electrical connections: power & network

M10

M31power & network

M45


M60

Technical solution for FPSO Cabinets with ‘late IO binding’ g


Software Configuration Flexibility

AI module FF

PID moduleFF

Pump moduleProfibus

Database-Area: M10 - Separation

FF FF Profibus

Modules in DCS Engineering Database

M10 – Separation skid M41 - MCC

H1

M10 Separation skid M41 MCC

Profibus

AI PID Pump

H1 Profibus


Classic & HART I/O Fieldbus I/O

Use of Bus Technology for FPSO

Safety Control & ElectricalDataMonitoringAcquisition

23

Digital system architecture that uses the power of field intelligence to improve FPSO performance


improve FPSO performance

Summary

Key success factors:F d ti Fi ldb l d d i l FPSO– Foundation Fieldbus already used in several FPSO projects

– Fieldbus architecture fits well with modular– Fieldbus architecture fits well with modular construction approach of FPSOs

– FDS discussion helps to optimize design and save p p gcost

– Tools and Documentation by Vendor

24– Training at all stages is vital for success


FF Design and project execution FPSO.ppt - · PDF filePIPA-II Petrobas 30,000 In commissioning...

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