A significant hydrocarbon discovery in the Baleine deepwater prospect prompted the development of a new oil field. To enhance production efficiency and cost-effectiveness, our client chose to repurpose an existing cylindrical Floating Production Storage and Offloading (FPSO) unit, implementing upgrades and modifications to align with the field’s operational and technical requirements.
As part of these upgrades, the installation of a Sulphate Removal Unit (SRU) was recognised as a key enhancement, ensuring the effective treatment and filtration of seawater prior to injection. Given the complexity of offshore operations, a reliable and integrated Control System was required to manage the SRU efficiently, enabling realtime monitoring, automation, and seamless communication with the FPSO’s existing infrastructure.
The Client
A leading supplier of offshore platform processing equipment and services in the international energy industry specialising in water treatment and chemical injection systems.
The Solution
The project involved the design, build, test, and supply of a Control System for the Sulphur Reduction Unit (SRU) on a Floating Production Storage and Offloading unit. The system infrastructure included one Unit Control Panel (UCP) and three Remote I/O Panels (RIOs).
- Design, material supply, assembly, and testing of the Unit Control Panel (UCP) complete with Rittal enclosure,
redundant Power Supply Units (PSUs), field marshalling terminals, and Schneider power distribution. - Design, material supply, assembly, and testing of the Remote I/O Panels certified for hazardous areas, equipped
with redundant Power Supply Units (PSUs) and field marshalling terminals. - Design, configuration, and testing of all PLC and HMI/SCADA software.
A state-of-the-art control solution was implemented using the Siemens Simatic PCS7 V9.1 hardware and software platform. This system was chosen for its proven reliability in field applications, ability to handle complex plant operations, and seamless integration of process control and safety systems. The Siemens PCS7 platform provided enhanced engineering flexibility, operational efficiency, and process optimisation, making it an ideal choice for a project of this scale and complexity.
Design and material supply of all panel components for both the Unit Control Panel (UCP) and the Remote I/O Panels. This included:
- Redundant Siemens 410-5H controller assembly, complete with redundant Power Supply, redundant
Central Processor Units and redundant Communications Processors. - Siemens ET200 SP HA I/O rack, complete with standard (non fail-safe) I/O modules and redundant Profinet
interface modules. - Bently Nevada 3500 Monitoring Racks
- Siemens PCS7 Operator Station (& Engineering Station) PC
- Siemens mounted Industrial Flat Panel 22” Touchscreen Display
Provision of comprehensive documentation including Functional Design Specification (Control Philosophy), Cyber Security Functional Design Specifications, logic flow-charts, I/O and device schedules, alarm schedules, Communication Interface Specification, Panel Heat Calculations, Panel Distribution & Communication Network Drawings, Wiring Schedules, Project Plan and Quality Plans.
In-house testing and Factory Acceptance Testing at Booth Welsh premises to demonstrate a fully working system against the Functional Design Specification (FDS). This was carried out over 3 separate dates as per our client request.
Project Challenges
01
Design Considerations
The ambient atmosphere was highly saline and corrosive, requiring all hazardous area equipment to be designed for durability against seawater spray and wash-down processes without adverse effects.
02
Material Lead Times
The global shortage of materials, particularly Siemens and Bently Nevada parts, resulted in extended lead times of up to 44 weeks. Booth Welsh accelerated our control panel delivery, overcoming scheduling challenges to complete the project three weeks early.
03
Hazardous Area Certification
The Remote I/O Panels required certification for installation within a Zone 2 hazardous area, which involved rigorous testing and compliance with IEC Ex and ATEX standards.
04
Integration with Existing Systems
Ensuring seamless integration with the existing Integrated Control and Safety System (ICSS) and motor drives/starters required detailed interface specifications and compatibility checks.
05
Cyber Security
Developing a robust Cyber Security Functional Design Specification to protect the control system from potential cyber threats was a critical aspect of the project.
The Benefits.
3 Weeks Accelerated Project Delivery
Innovative PCS Design using latest Siemens PCS & I/O Hardware & Software solution.
Hazardous Area Certification