The Background.
Booth Welsh was commissioned to provide the Control System for the Sulphate Reduction Unit (SRU) on the FPSO that has been in production in the Brazilian located Baleia Azul Field since September 2012. The FPSO was an upgrade to an existing platform (FPSO Espadarte).
Initial production figures of the new FPSO were recorded as 20,000 barrels per day with a forecasted increase to 100,000 barrels per day. This significant production increase could only be achieved with successful water injection – to which the SRU is a critical pre-requisite of.
The end client needed a reliable and robust control system and stated a preference for a redundant Siemens PCS7 System with WinCC SCADA. Plant operations specified a need for both remote and local control of the SRU package as well as an interface to the FPSO Integrated Control System for process data logging and alarms as well as site safety functionality.
The Booth Welsh project scope included:
Design, development and testing of four control panels including:
- One remote control panel
- Three locally distributed I/O panels
Software design, development and testing for the package process areas including:
- Upstream Pre-treatment
- Sulphate Removal
- Chemical Dosing
- High Pressure Pumps
- Clean in Process (CIP)
On-site support during commissioning activities:
- Modifications to hardware and software configuration
- Reviewing and amending design documentation
Increase the FPSO plant production capabilities from 20k to 100k barrels of oil per day
Commissioning activities completed within the end client’s schedule
System I/O count of over 150 including both I.S. and Non-I.S. type
Significantly reduced plant maintenance and downtime costs due to the data logging and trending features configured by BW
The Client
Our client is the largest single supplier/operator of sulphate reduction membrane systems, and has been designing water treatment applications for over 100 years. Operations in 57 countries, with 135 business units. The end client is a multi-national petroleum corporation.
The Solution.
Booth Welsh was able to provide the client with an integrated Design, Manufacture and Test solution to meet both their aspirations and regulatory requirements. We have executed over 30 such projects for the client and have been working successfully together for over 20 years.
Key to the success of this specific project was the development of the software modules to meet the specific process requirements. To ensure that the resultant system would meet the customers’ expectations Booth Welsh Control Engineers worked together with the client to understand the control requirements, translating them into a Functional Design Specification (FDS).
The software solution was developed from a proven, modular, tested and documented series of modules, capable of re-use on similar pieces of plant with minimal alterations, coupled with proven hardware.
A reliable and robust redundant pair of Siemans S7-400 series controllers.
- Sequence control of all SRU process areas
- Trip and Interlock functionality of field devices (Pumps, Valves, Heaters).
Distributed I/O racks comprising the following:
- Signal allocation of both I.S. and Non-I.S. type.
- Redundant ET 200M Rack I/O with Profibus DP communications
- Varied I/O modules for instrumentation signals including Analogue In, Analogue Out, Digital In, Digital Out and RTD Temperature.
A comprehensive SCADA system offering:
- Clear and concise process mimics with intuitive navigation, symbols and messages for intuitive plant operation.
- Plant alarms to highlight deviances within the process operating parameters.
- Process data logging with trending for in-depth analysis (diagnostics, Condition based maintenance and performance monitoring).
Communications links to the FPSO Integrated Control System.
- OPC protocol employed to transmit plant process parameters and alarms to central control system.
- Hard-wired links to/from central control system to facilitate safety shutdown functionality.
Extensive testing of both the hardware and software was carried out at the factory acceptance testing stage to minimise site-commissioning time. Successfully commissioned between in line with the end client’s commissioning schedule.
The Benefits.
This was a task successfully undertaken by our highly skilled systems engineering team which is built up of Chartered and Graduate engineers who have a vast knowledge base developed from many years’ practice across a wide variety of industries. Together they deliver Control System solutions for leading PLC, SCADA and DCS systems, including well known platforms such as Siemens PCS7, Emerson Delta-V and Rockwell Allen Bradley.
Their close collaboration with our in-house Process, Design & Engineering Divisions allows for the offering of a unique design and panel build service, allowing clients to benefit from a seamless process which translates into significant savings in project costs and timescales.
SCADA Software Development, platform based using proven software, encompassing lessons learnt and best practice.
An integrated hardware and software solution with unique design and panel build service seamlessly co-ordinated in-house
Tailored System Interface, familiarity for Operational & Commissioning staff.
Proactive attitude and flexibility of engineers, who understand client needs and are responsive to project requirements