Industrial Automationand Optimisation

AdvancedFPSO and Subsea Control Solutions

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FPSO AND SUBSEA AUTOMATION, INTEGRATION AND OPTIMISATION

INTEGRATED CONTROL & SAFEGUARDING SYSTEM (ICSS)

Reduced risk due to extensive expertise in implementing advanced ICSS solutions to global players in the FPSO arena. We are experts in automating, integrating, and optimizing core FPSO functionality (marine systems, turret, topside and F&G), while adhering to stringent international regulatory and safety standards.

PACKAGE INTEGRATION

We use our multi-platform capability and end-to-end integration expertise with OLE for Process Control (OPC) and other protocols to fully interface OEM packages (boiler, power generators, etc,) with the ICSS. All data is available for effective remote control and operation.

POWER MANAGEMENT SYSTEM (PMS)

Our approach is to develop power management as a component within the ICSS. This eases maintenance and reduces dependence on specialist 3rd party providers. We provide a solution that is not a black box, with limited, or fixed functionality.

OPTIMISATION

Increased safety, maximised production up-time, and reduced operating costs directly attributable to our integrated solutions for predictive maintenance, intelligent alarm management, and closed-loop control optimisation. Safe, stable and predictable plants yield higher output for the same input costs, thereby maximizing profit.

TELEMETRY

Proven solution for wireless communications where safety and reliability are imperative. Typically installed for safety communications between the vessel and the turret, and between the vessel and the CALM buoy for custody transfer. Two-out-of three voting (SIL 3) improves protection of assets and prevents environmental damage.

MAINTENANCE

A range of solutions can be selected and tailored to meet specific requirements, from global 24/7 on-site engineering support, through to remote support and problem solving. Issues are tracked, escalated and closed out with full management reports. Faults can be rapidly simulated on in-office hardware for robust and permanent resolution.

FPSO AUTOMATION

SUBSEA AND HPU CONTROL

SIMULATORS

One-to-one replication of real-world functionality ensures operators and maintenance personnel are well prepared for plant operation. Reusing ICSS and MCS configuration code in the simulators reduces duplicate-engineering effort.

HYDRAULIC POWER UNIT (HPU)

Our solution is to tightly integrate the HPU control and safeguarding logic with the MCS by utilizing a common platform. Integrating failsafe communication streamlines and optimises the interaction between the two systems.

MASTER CONTROL STATION (MCS)

The MCS is architected and designed bottom-up for high availability, and reliable operation. The solution is com-prised of hard PLCs, with redundancy at all levels. The system is fault tolerant, with bumpless switchover in the event of a system upset. The MCS can be engineered to run on the same platform as the topside ICSS, or can easily be integrated with the topside systems through use of open connectivity standards.

OUR GLOBAL REACH

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DEEP PANUKE PLATFORMFull supply of ICSS and PIMS system offshore and onshore, store-forward data transfer via satellite link from the platform to onshore.• Size:3,400 hardwired I/O, and

5,000 tags for the PIMS.• Project duration: 1 Year shipyard;

2 years on location.• Highlight: Advanced reports to

comply with the Canada - Nova Scotia Offshore Petroleum Board requirements.

MOPUSTORFull supply of ICSS• Size: 3,750 hardwired and 3,000

OPC I/O.• Project duration: 1.5 Year

shipyard; 2.5 years on location.• Highlight: Project was executed in

full compliance to the Norsok and IEC standards.

TURKMENISTANFull supply of ICSS• Size: 1,000 hardwired and 400 modbus I/O.• Project duration: 1 year shipyard; 6 months on

location.• Highlight: new-build Mopu included extensive

engineering effort to meet required standards.

FPSO FRADEFull supply of ICSS with fully integrated alarm management.• Project duration: 1 year shipyard;

6 months on location.• Size:4,500 hardwired and 3,000

OPC.• Highlight: Fully integrated alarm-

management improves safety, and allows for more stable operation, and improved yields. Full compliance with EEMUA and ISA 18.02 standards.

FPSO AKPO (CALM BUOY)Telemetry system between CALM buoy and FPSO.• Size: Radio communication link.• Project duration: 3 years shipyard

(intermittent); 6 months on location.

• Highlight: Successful supply of a fully redundant, three-way radio link between the FPSO, CALM Buoy and off-loading tanker.

FPSO MONDOFull supply of ICSS and integrated alarm management, operator training simulator and Subsea system.• Size: ICSS 3,400 hardwired and 3,500 OPC I/O; 10,000 soft Subsea I/O.• Project duration: 3 years shipyard; 4 months on location• Highlight: First fully integrated PCS7 project for the ICSS and Subsea systems.

FPSO OKHAFull supply of the ICSS, an operator training simulator, and control loop optimisation.• Size: ICSS 6,500 hardwired I/O

with integrated MCC, and 3,500 OPC I/O.

• Project duration: 1.5 years shipyard; 6 months on location.

• Highlight: Complex tuning effort reduced from months to a few days. Full IEC61511 compliant project.

Offshore Experience ICSS

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Angola Kizomba A (FPSO) •Kizomba B (FPSO) •Kuito (FPSO) • •Mondo (FPSO) • • • •N’Goma (FPSO) • • •Saxi Batuque (FPSO) • • •Xikomba (FPSO) • •

AustraliaOkha (FPSO) • • • •

Brazil Anchieta (FPSO) • • •BC10 (FPSO) • ∆

Capixaba (FPSO) • ∆

Frade (FPSO) • • • •MarlimSul (FPSO) •

CanadaDeep Panuke PFC (Platform) • ∆

Equatorial GuineaAseng (FPSO) • ∆

Serpentina (FPSO) •Malaysia •

Kikeh (FPSO) •Nigeria

Akpo (FPSO – CALM Buoy) *North Sea

MopuStor (Jack-up) • •South Africa

FA Platform (Platform) • •Turkmenistan

Turkmenistan (FSO) • •Turkmenistan (MOPU) • •

* Telemetry ∆ Offline optimisation

HQ: Johannesburg, RSA

Secunda Office

Vanderbijlpark Office

Westville Office

Houston Office

London Office

Singapore Office

Project Location

Office Locations

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SELECTED DELIVERY SUCCESSES

SUBSEA MCS CASE EXAMPLE – FPSOs KIZOMBA A & B (ANGOLA)We initially developed a standard subsea library, which was then tested “to fail”, to ensure individual components perform reliably under foreseeable conditions. Library components were then grouped to form modular units e.g. production well, manifold, etc., and once again tested rigorously. All the modular units were then integrated using the C&E, interlock schedules and control strategies.

The hardware for the project was a high-availability, fault tolerant, hardened PLC system, comprising of eight redundant pairs, with four sets of servers and client stations. The HPU (failsafe system for the subsea control devices on the subsea trees, and one of the more critical units within the system) was fully integrated with the MCS to allow for seamless, optimised control.

After extensive internal and external factory acceptance testing using simulators, the MCS and HPU were connected to the physical subsea tree for enhanced factory acceptance tests, whereby the end-to-end integration of the control system with the subsea devices was witnessed, validated and verified.

The system was then installed, and site-integration testing executed; first with simulators, and finally with the physical trees, on location at the field. Tests included all devices, strategies, shutdowns and interlocks. Thereafter the system was commissioned and declared “ready for oil.”

Currently we provide periodic health care and maintenance checks on the system.

FEED STUDY INPUTMoore participates extensively in FEED studies to provide early architectural solutions, safety requirements, and accurate pricing to aid end customers with their FEED study inputs.

OUR COMPREHENSIVE PROJECT APPROACH

VALUE OPTIMISATIONALARM

MANAGEMENT

BASE-LAYER OPTIMISATION

PREDICTIVE MAINTENANCE

PRODUCTION OPTIMISATION

PRODUCTION SCHEDULING & MONITORING

AUTOMATED DATA COLLECTION &

CONSOLIDATION

DATA INTEGRATION

Measure and audit plant safety, prevent spurious shutdowns and stabilize production outputs – the result is improved profits due to production increases for the same given value of input costs.

Maximise plant output yields by ensuring the process is always tuned to current operating conditions – increased yields result in increased profits.

Measure critical-asset performance and prevent damage – monitor real-time efficiencies and power consumptions to manage maintenance budgets based on real plant requirements .

Monitoring equipment effectiveness, asset availability and performance, and repair requirements versus budgeting for routine maintenance only – discover which assets are affecting profits, and why.

Maximise production plan within available plant and asset constraints – see how plant performance measures up against plan and budget.

Production and performance - from remote plants and Head Office – create centralised data warehouse so there is one version of the truth to manage and correct the real plant and production problems.

Connectivity and value-added OPC tools to connect, encrypt, secure, monitor, manipulate, transfer, report, and manage data across your plants.

ICSS CASE EXAMPLE – FPSO OKHA (AUSTRALIA) The project was to supply the complete ICSS and operator training simulator for the OKHA disconnectable FPSO.

The project was executed in full compliance with IEC 61511, considering the full IEC life cycle. Work was completed in 10 months, ahead of the exhaustive factory acceptance test (FAT). Hardware consisted of multiple redundant servers, clients, redundant CPU’s and I/O. Extensive interfacing to various 3rdparty vendors across multiple platforms was required.

In parallel a full operator training simulator was built on the same ICSS platform to emulate the FPSO control system exactly, thus reducing training time for new operations personnel.

All work was completed in compliance with our IS0 9002 quality system, with documented work-flows, policies and procedures to ensure that all deliverables had undergone mandated quality checks.

Moore deployed an experienced construction and commissioning team to the shipyard, to ensure the control system was ready on time for first oil. The customer’s stringent quality requirements and demanding schedule were all met on time, and on budget.

ALARM MANAGEMENT CASE EXAMPLE – FPSO FRADE (BRAZIL)FPSO FRADE specified the highest standards for alarm management and safety, and hence chose our alarm-management solution .

The solution integrated with the ICSS, allowing for critical alarms and operator actions to be stored, tracked and reported via the web-based HMI. Standard web-based reports allow users to immediately identify poorly configured alarms and nuisance alarms (bad actors). Continuous improvements and long-term maintenance initiatives were easily established to optimise alarm performance.

Reports provided key information on safety-related incidents such as the number of shut-down alarms, when these occurred, the number and duration of alarms that have been locked out, and the number and duration of alarm manual overrides. This information provided critical insight into how safely the vessel was being operated, and is being used to preempt major plant catastrophes.

In addition, the solution is being effectively used as a root-cause analysis tool, and to manage MOC (management of change) component audits by comparing live ICSS alarm settings against designed settings.

DETAILED ENGINEERINGMoore participates extensively in FEED studies to provide early architectural solutions, safety requirements, and accurate pricing to aid end customers with their FEED study inputs.

FACTORY ACCEPTANCE TESTING (FAT)Comprehensive FATs reduce the time spent commissioning and fault finding on site. Our audited approach using simulators provides assurance that systems perform in situ as anticipated.

MAINTENANCE AND SUPPORTAfter system go-live we provide comprehensive maintenance services to maximise plant safety and uptime, respond to crises, and perform routine-maintenance operations.

Key Clients: Contact us:

info@moore.co.za

South Africa:Head Office (Johannesburg)

Tel: +27 (11) 466 1673

(Vanderbijlpark) - Tel: +27 (16) 932 4471

(Secunda) - Tel: +27 (17) 631 2744

(Westville) - Tel: +27 (31) 003 3100

USA (Houston)Tel: +1 832-299-6759

Europe (London)Tel: +44 777 265 1605

SingaporeTel: +65 6742 0776

www.moore.co.za

Copyright Moore Process Controls Pty (Ltd)

Moore is an equal-opportunities employer.We are ISO 9001:2008 and OHSAS 18001:2007 accredited, and IEC 61508 and IEC

61511 certified.

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