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OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
P. Troianiello - Fores Engineering – Rosetti Marino Group
The benefits of modern IntegratedControl and Safety Systems
architectures for FPSO facilities.
A. Gariboldi - Siemens Industry Sector IA/DT
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
Topics
FPSO - Definition
FPSO - Features
Off-Shore Project today’s core requirements
FPSO customer’s trend requirements
A real application of ICSS
Where we can have benefits
Conclusions
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
FPSO – DefinitionA Floating Production, Storage and Offloading (FPSO) unit is a floating vessel used bythe Offshore Oil& Gas Industry for the processing of hydrocarbons and for storage ofoil. An FPSO vessel is designed to receive hydrocarbons produced from nearby platformor subsea template, process them, and store oil until it can be offloaded onto a tanker or,less frequently, transported through a pipeline.
(by Wikipedia)
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
Hull refurbishment
Topside (process area) implementation
Turret Implementation
FPSOs can be a conversion of an oil tanker or can be a vessel built speciallyfor the application.
In case of conversion of an oil tanker the following steps are carried out:
FPSO - Features
HULL & TANKS TURRETVESSEL
TOPSIDE
Wheel Room, Engine Room, Accomodation Umbilical Cords and Drillling
Process Plants
300/400 meters
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
Today’s core requirements
Enhancedquality
Reducedcosts
Minimizedtime
>>> Reduction of time to «first oil» = earlier production = earlier ROI
Off-Shore Project Core requirements: • How to make engineering more cost-favorable with improved quality?• How to accelerate time to electrical-instrumental installation completion?• How to accelerate time to production with faster commissionig & start-up?• How to reduce complexity and interfaces during operational and maintenance activities?
2- 6%15-30%
Piping, Vessels &Structure
Rotating Equip
Automation
Bulks
“Suppliers offering a truly integrated offering of process and safety are saving end users substantial project costs in engineering and lifecycle expense.”
Impact on Operations Over Time
Source: ARC
Percent age of Project Spent
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
FPSO Customer Requirements• Actual Trend: Overall costs optimization
Don’t compromise qualityDon’t compromise safetyTime to commissioning reductionUse of modern technologies
Integrated Control & Safety SystemPCS ECS F&G/ESD
TopsideF&GVessel
Very integrated, that is from the same manufacturer
F&G Integrity Level SIL 2 ESD Integrity Level SIL 3
Accomodation Fire Detectionbased on addressable system
Removal of hardwired linksbetween the systems by the replacement with «safetybuses» and «certifiedprotocols».
Reduction of process hardware linksand junction boxes by using remote I/O boxes suitable for field installations
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
Power
Fire Brig. recvd.
Fire vent. activ.
Fire ext.. acktivated
0
ALARM
?
C
987
654321
Silence buzzer
Silence sounders
Reset
More Alarms
Prewarning
Early warning
System faultFunction disabledTest
Fault
Self Verify
Central clock
Central Control Room Wheel Room Engine Room
Operator Workstations SOER
F&G Operator WS & Video wall
F&G Operator WS F&G Operator WS
PCS ECS F&G/ESDTopside
F&GVessel
Local Equipment Room OR Central Equipment Room
Field Local Control PanelsEex-d, Eex-i, Eex-p
RIO 1 LCP RIO 2 LCP RIO N LCP
Accomodation
AddressableLoops
PRO
FISA
FE
Safe Data Link
SIL 2 or 3 SIL 2 or 3
SIL 2 or 3RED
UN
DA
NT
PRO
FIB
US-
DP
RED
UN
DA
NT
PRO
FIB
US-
DP
RED
UN
DA
NT
PRO
FIB
US-
DP
REDUNDANT RING TERMINAL BUS ETHERNET
REDUNDANT OPTICAL RING TERMINAL BUS ETHERNET
OPTICAL REDUNDANT PROFIBUS DP
PCS/ECSRedundant
Server
ESD/F&GRedundant
Server
HISTORIANRedundant
Server
EngineeringWorkstation
ICCS Overall Architecture
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
Power
Fire Brig. recvd.
Fire vent. a ctiv.
Fire ext. . acktivated
0
ALARM
?
C
987
654
321
Silence buzzer
S ilence sounders
Reset
M ore Alarms
Prewarning
Early warn ing
System fault
F unctio n disabledT est
F ault
Se lf Ve rify
F&G
PCSECSF&G/ESD
About 300/400 meters
Central Control RoomWheelRoom
EngineRoom
LER
Accomodation
Process Field Junction Boxes
About 250 mt
About 120 mt
ICCS Overall Architecture
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
REDUNDANT RING TERMINAL BUS ETHERNET 100Mbits/s
RIO LCP Module 1 RIO LCP Module 2 RIO LCP Module 3 RIO LCP Module 4 RIO LCP Module 5 RIO LCP Module 6
RIO LCP Module 7 RIO LCP Module 8 RIO LCP Module 9 RIO LCP Module 10 RIO LCP Module 11 RIO LCP Module 12
Process Field Junction Boxes (Eex-d, Eex-i, Eex-p or in Safe Area according Hazardous Area)
PCS Panel ECS Panel
MV Switchboard
L.Q. Switchboard Emergency MCC
LV Switchboard 1 LV Switchboard 2
MCC Switchboard
GT1
GT2Electrical Cabinet s in Safe Room
AVG DIST = 25 mt
AVG DIST =150 mt
2000 I/O1000 I/O
Real application - Control
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
F&G/ESD Topside (located in LER)
F&G SYSTEMSIL2 AK4
REDUNDANT I/O MODULE(Q.ty Nr. 2+2 AI Module;
1+1 DI Module; 1+1DO Module)
ESD SYSTEMSIL3
ESD SYSTEMSIL2
SINGLE I/O
SINGLE I/O
VESSELF&G SYSTEM
SIL2
SINGLE I/O
F&G Vessel (located in CCR)
PROFISAFE DATA EXCHANGE SIL 3 on Ethernet
PRO
FISA
FE S
IL3
PRO
FISA
FE S
IL 2
DIST =100 mt
Power
Fire Brig. recvd.
Fire vent. activ.
Fire ext.. acktivated
0
ALARM
?
C
987
654321
Silence buzzer
Silence sounders
Reset
More Alarms
Prewarning
Early warning
System faultFunction disabled
Test
Fault
Self Verify
ADRESSABLE LOOPS SIL 2
VESSELADRESSABLE
F&G SIL2
2000 I/Os 700 I/Os
300 SW Signals(Shutdown causes) instead of 300 I/O
600 Devices
800
SW S
igna
lsin
stea
dof
800
I/O
Real application - Safety
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
Real application – Cabling savingCable saving (12 pairs shielded armoured), related cable trays,
junction boxes, bulk materials and installations activities.
PCS remote rack I/OPCS Panel
ECS remote rack I/OECS Panel
F&G remote rack I/OF&G Topside
F&G vesselF&G Topside
Addressable PanelF&G Vessel
Addressable PanelField Loops
Remember also a simpler field engineering !
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
Real application – New safety sw toolsToday technologies offers safety software tools able to save costs during the Safety
Lifecycle from the engineering to operation and maintenance phases.
Risk Analysis and Protection Layer DesignSub-clause 8
Allocation of Safety Functions to Safety Instrumented Systemsor other means of risk reduction
Sub-clause 9
Safety Requirements Specification for the Safety
Instrumented System Sub-clause 10
Design and Development of Safety Instrumented
System Sub-clause 11
Design and Development of other means of Risk
ReductionSub-clause 9
Installation, Commissioning and ValidationSub-clause 14
Operation and MaintenanceSub-clause 15
ModificationSub-clause 15.4
DecommissioningSub-clause 16
Management of
Functional Safety and Functional
Safety Assessment
Sub-clause 5
Safety Lifecycle Structure
and Planning
Sub-clause 6.2
Verification
Sub-clause 7,
12.7
Risk Analysis and Protection Layer DesignSub-clause 8
Allocation of Safety Functions to Safety Instrumented Systemsor other means of risk reduction
Sub-clause 9
Safety Requirements Specification for the Safety
Instrumented System Sub-clause 10
Design and Development of Safety Instrumented
System Sub-clause 11
Design and Development of other means of Risk
ReductionSub-clause 9
Installation, Commissioning and ValidationSub-clause 14
Operation and MaintenanceSub-clause 15
ModificationSub-clause 15.4
DecommissioningSub-clause 16
Management of
Functional Safety and Functional
Safety Assessment
Sub-clause 5
Safety Lifecycle Structure
and Planning
Sub-clause 6.2
Verification
Sub-clause 7,
12.7
Cause & Effects Engineering, Operations and Maintenance Tool- Eliminates translation errors by automatically generating the logics- Automatically generates HMI faceplate to visualize matrix - Interface for maintenance overrides and I/O simulation during FAT or SAT- Automatically generates change the documentation (IEC 61511) and the Events Log
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
ICSS FEATURES
Integrated Control & Safety System from the same
manufacter
Distributed Remote I/Os on Profibus or
High Speed Ethernet
Certified Bus with protocol
according IEC61508/61511
Addressable Fire Control Panel
according IEC61508/61511
vs. vs. vs. vs.
PROJECTLIFE PHASE
Multiple manufactures
Traditional point-to point hardwired
links
Traditional safety hardwired link
Not Adressable
Engineering Yes Yes Yes Yes
Cabling Material Yes Yes Yes
Installation Yes Yes Yes
Commissioning Yes Yes Yes Yes
Operation Yes
Maintenance Yes Yes Yes Yes
Where we can have benefits?
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
ArchitectureSemplicity
Technical Innovation
OverallCosts
Therefore, nowadays, EPC contractors or End-User have new opportunities to optimize the costs ofthe overall plant lifecycle, taking advantage of the new technologies offered by Control & Safetysystems, even though the more difficult barrier to overcome are the old cultural heritages that oftenwe could have, despite we live in the “age of the networks”.
Interfaces
New features of Integrated Control & Safety System combined with
certified safety buses and addressable F&G systems
But the most consistent financial benefit, due to anearlier installation and commissioning, is the timereduction of an earlier “First Oil”.
This economical value could be definitely ten timesgreater than the saving obtained during the project,depending on the expected daily plant production.
Conclusions
OMC 2013 – Ravenna – Italy – Workshop ANINP – 21 marzo 2013
Thank you!Fores Engineering is an Italian company established in 1992,part of the Rosetti Marino Group, specialized in the ProjectManagement, Engineering, Procurement, Integration,Construction and Commissioning of systems for the Oil & Gasboth upstream and downstream, in the field of Offshore platformsand Onshore plants, Petrochemical, Chemical and Power plantfields. Its main products are Control & Safety Systems,Telecommunication & Security Systems, Skid Mounted PackageUnits, Wellhead Control Panels, Process Analyzer Systems,Equipped Shelters.
Siemens is a global company operating in the sectors ofindustry, energy and healthcare, providing also solutions for theinfrastructure of cities and metropolitan areas.Distinguishable from over 165 years of innovation, quality,reliability, technological excellence, Siemens is the leading globalprovider of environmentally sustainable technologies,Industry SectorThe Siemens Industry Sector is a leading global provider ofinnovative products and solutions to customers in the industry.Large market experience-based services and software forindustrial processes are some of the main levers that we use toincrease productivity, efficiency and flexibility of our customers.