The benefits of modern Integrated Control and Safety ... · OMC 2013 – Ravenna – Italy –...

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


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


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)


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


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


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


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


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


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


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


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 !


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


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?


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


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.

The benefits of modern Integrated Control and Safety ... · OMC 2013 – Ravenna – Italy –...

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