The Kizomba A project includes one Surface Wellhead Platform (SWHP) and a Floating Production Storage and Offloading (FPSO) vessel together with an offloading buoy and sub sea production systems.
The operation of an FPSO and SWHP in such a remote location necessitates state-of-the art, integrated Emergency Shutdown (ESD), Process Shutdown (PSD), and Fire & Gas (F&G) systems. These crucial systems must offer the highest achievable levels of performance and integrity and be readily maintainable online without jeopardizing or interrupting operations.
They also demand a minimal “footprint” and must meet or exceed all relevant global standards including, at a minimum, IEC61508 for SIL3, TÜV Rheinland, NFPA 72, FM, UL, CE, CSA, ANSI/FM 3260, ATEX, and
ISO 13702.
Triconex TMR Architecture for ESD/PSD/F&G
ExxonMobil chose a MICC (Main Instrument and Controls Contractor), who subcontracted
to Triconex. The MICC scope was driven by the E&C’s (Engineers and Constructors) responsible for design/construction of the hull, topsides, and the LERs (Local Equipment Rooms), which contained the process control hardware. The changing scope, and the fact that LERs were often being constructed in different locations, presented a challenge that Triconex was prepared to meet.
The MICC selected Triconex, the #1 ESD supplier in the world for seven consecutive years1, to be the solution provider for ESD, PSD and F&G systems. The installed Triconex TMR (Triple Modular Redundant) solution achieves optimal availability (safety) and reliability (spurious trip elimination) versus dual/Quad and simplex PLC architectures. Dual/ Quad systems are fail-safe and must rely solely on fallible diagnostics, which often means a trip when the fault cannot be isolated. Simplex systems were eliminated because of the unacceptable availability and reliability inherent in this architecture and the criticality of the Kizomba applications. With the application of state-of-the-art hardware and software implemented fault tolerance (HIFT & SIFT), the Triconex TMR solution is both fault tolerant and fail safe, providing the highest achievable combination of availability andreliability.
Logic solver integrity is essential, but the solution must also be validated to meet the diverse and stringent requirements mandated by such a critical application.
Invensys Triconex’s unique ability to deliver a combination ESD and F&G solution certified to NFPA 72 by a NRTL (Nationally Recognized Testing Laboratory) with a logic solver certified to SIL 3 by TUV in accordance with IEC 61508 inspired confidence.
In addition, the solution includes combustible gas detectors certified to CSA 22.2, a family of flame detectors certified to the new ANSI/FM 3260 flame performance specifications, and all devices for hazardous locations certified to ATEX. The entire system including fire & gas detection, general alarm, fire protection and ESD can also be designed, installed and maintained in accordance with ISO13702 for the petroleum and natural gas industries.
This thoroughly validated solution is interfaced to with a single, full-function HMI (Human Machine Interface) and supports both point-to-point and addressable F&G I/O for both detection and suppression.
Finally, that the solution was jointly developed with Kidde Group Companies, world-recognized solutions provider for both industrial and commercial F&G applications, and Invensys Triconex assured that both the technology and the application expertise was readily available.
The final solution resulted in a combination ESD/F&G system employing Triconex remote I/O, addressable smoke, thermal and alarm for living areas, dedicated firstout alarm and mimic panels for H2S detection and fire and gas monitoring for the drilling deck, and deluge zone and valve control.
The Triconex TMR solution’s unrestricted fiber optic remote I/O, high density chassis, and high density AI and DI modules allowed optimal distribution of systems into the Kizomba LERs while minimizing “footprint” and the use of “home run” copper wire. Further, the Triconex solution provided superior maintainability through online hardware maintenance access, modular application program constructs, and the ability to change control programs on-line without process interruption.
With nearly 4,000 systems world wide and 300,000,000 operating hours without a single unsafe error, Triconex TMR solutions are arguably the most proven, durable, andrugged in the world.
Triconex also faced the challenge of testing all the Kizomba systems, most of which were broken up into separate parts in LERs that were being constructed on various continents. The main issue was how to effectively test a remote I/O chassis when it was separated from the Main Processor (MP) set.
Triconex went to the drawing board and developed a suitcase-sized, mobile test system that has an MP, communication module(s), and remote I/O support. With this tool, Triconex engineers can fly to an international location, secure a few connections, and FAT the remote I/O as if the main processors were right there. This practice resulted in seamless, effective connections when the LERs were finally assembled on the vessel.
Project Philosophy and Implementation
The Triconex “Customer Centric” approach systematically produces repeated successes on complex international projects. Triconex’s experience has demonstrated that early involvement during the engineering phase of major projects tends to minimize rework, optimize design, and promote adherence to budget. Both Triconex Premier Consulting Services (responsible for upfront engineering) and Triconex Project Operations (responsible for project execution) supported efforts during the Kizomba Front End Engineering and Design (FEED) phase.
The next step is a formal design review with the client prior to start of detail design work. Failure to implement this review could result in expensive changes later in the project. Triconex Engineers document all changes (both internal and client initiated), modify appropriate documentation, quantify the affect on costs and schedule, and submit them to project management for approval. Once the project scope is finalized, Triconex builds “scope creep” safeguards into the project management system to prevent significant, expensive changes. These safeguards include a comprehensive, proven project change management procedure.
A typical Triconex execution followed where, on a project the size of Kizomba, thousands of prioritized activities proceeded in parallel and in series. The MICC, Triconex, and ExxonMobil coordinated to resolve issues, evaluate scope, prioritize resources, and manage the inevitable changes. The systems were then packed for international transport and sent to various fabrication yards for integration into the LERs.
The resulting modules were subsequently assembled on the FPSO and SWHP. Lastly, MICC service engineers with available Triconex guidance went to the field to support LER testing, module testing, and site acceptance testing, insuring the systems were prepared to protect the vessel and support structures at first oil.
Project Summary
Being truly “Customer Centric” begins with identifying and prioritizing the customer’s requirements, then relentlessly pursuing satisfaction from order placement through facility start-up. Careful identification of required equipment architecture, enabling technologies, and required partners follows. Triconex then implements a time-tested project execution methodology beginning with early involvement, moving to a candid exchange to refine requirements and deliverables, and finishing with an on-time, on-budget execution satisfying all project requirements.
