ESD System upgrade


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FEED Stdy to upgrade FPSO TER ESD Solid State system with the best avilable option

ESD System upgrade

  1. 1. Presentation School of Science & Engineering MSc Applied Instrumentation & Control MSc I&C, GCAL
  2. 2. FPSO * Turret Equipment Room Emergency Shutdown (TER ESD) System Upgrade ( A project for Oil & Gas Platform at North Sea) * Floating Production, Storage and Offloading Presented By Syed Naqvi
  3. 3. Agenda <ul><li>TER ESD Spare Capacity or I/O capacity </li></ul><ul><li>Techniques to increase spare capacity </li></ul>MSc I&C, GCAL
  4. 4. ESD Definition <ul><li>Emergency Shutdown System in Oil & Gas? </li></ul><ul><ul><li>Emergency Shutdown System (ESD) is designed to minimize the consequences of emergency situations, related to typically uncontrolled flooding, escape of hydrocarbons, or outbreak of fire in hydrocarbon carrying areas or areas which may otherwise be hazardous </li></ul></ul><ul><ul><li>Shutdown of part systems and equipment </li></ul></ul><ul><ul><li>Isolate hydrocarbon inventories </li></ul></ul><ul><ul><li>Isolate electrical equipment *) </li></ul></ul><ul><ul><li>Prevent escalation of events </li></ul></ul><ul><ul><li>Stop hydrocarbon flow </li></ul></ul><ul><li>*) May alternatively form part of the fire/gas detection and protection system. </li></ul>MSc I&C, GCAL
  5. 5. Turret Equipment Room Emergency Shutdown System (TER ESD) <ul><li>ESD has two parts TER and CCR (Central Control Room). </li></ul><ul><li>TER ESD is a fault tolerant, triplicated Logic; solid state shutdown system. </li></ul><ul><li>Data acquisition through 90-30 PLC. </li></ul>MSc I&C, GCAL
  6. 6. The Problem MSc I&C, GCAL
  7. 7. TER ESD Spare Capacity and Modifications <ul><li>Input sub-system has the capacity for expansion. </li></ul><ul><li>Only very limited expansion to the existing program/shutdown logic can be supported. </li></ul><ul><li>All outputs are utilized. </li></ul><ul><li>The Problem </li></ul><ul><li>Hence no future modifications will be guaranteed. </li></ul>MSc I&C, GCAL
  8. 8. Spare Capacity Requirements <ul><li>Minimum BP Requirements or 20% Capacity Expansion. </li></ul><ul><li>Worst case or 50% Capacity Expansion </li></ul>MSc I&C, GCAL
  9. 9. Techniques to Enhance Spare Capacity <ul><li>Expansion To Existing TER ESD </li></ul><ul><li>Redesign 2oo3 Relay Voter unit </li></ul><ul><li>Partial Expansion </li></ul><ul><li>System Replacement </li></ul>MSc I&C, GCAL
  10. 10. Expansion of Existing System (1) <ul><li>Hence no future modifications possible in existing S600 system configuration. </li></ul>MSc I&C, GCAL
  11. 11. Partial Expansion MSc I&C, GCAL
  12. 12. Partial Expansion (1) <ul><li>Expansion Requirements </li></ul><ul><ul><li>Two System Bays required. </li></ul></ul><ul><ul><li>including Data Acquisition PLC plus input racks. </li></ul></ul><ul><li>It is recommended not to select this option because </li></ul><ul><ul><li>Physical Space limitations in TER. </li></ul></ul><ul><ul><li>Distance limitations outside TER. </li></ul></ul>MSc I&C, GCAL ESD 50% Spare Capacity 20% Spare Capacity   Program Modules Program racks 2oo3 Voting Units Output racks Program Modules Program Racks 2oo3 Voting Units Output Racks TER 12 2 18 5 6 1 8 2
  13. 13. Redesign 2oo3 Voter Unit (1) <ul><li>Substantially Retain and Redesign Existing System. </li></ul><ul><li>One 2oo3 unit consists of 4 SR relays. </li></ul><ul><li>It is not recommended because </li></ul><ul><ul><li>Logic still limited by number of voting gates. </li></ul></ul><ul><ul><li>No validity of design before FEED study. </li></ul></ul>MSc I&C, GCAL
  14. 14. TER ESD Replacement/Upgrade (1) <ul><li>Destruct Existing System and Replace with new system in existing panels </li></ul><ul><li>Benefits offered over previous techniques. </li></ul><ul><ul><li>Less Engineering cost </li></ul></ul><ul><ul><li>Obsolescence extended. </li></ul></ul><ul><ul><li>Smaller footprint </li></ul></ul><ul><ul><li>Can have onshore test facility. </li></ul></ul><ul><ul><li>Large number of I/O within existing footprint. </li></ul></ul><ul><ul><li>Ease of modification. </li></ul></ul>MSc I&C, GCAL
  15. 15. TER ESD Replacement/Upgrade (2) <ul><ul><li>Safety Systems considered </li></ul></ul><ul><ul><ul><ul><li>TRUSTED TMR* by ICS Triplex </li></ul></ul></ul></ul><ul><ul><ul><ul><li>TRICON TMR by TRICONEX </li></ul></ul></ul></ul><ul><ul><ul><ul><li>AADVANCE TMR by ICS Triplex </li></ul></ul></ul></ul><ul><ul><ul><ul><li>GMR TMR (Genius Modular Redundancy) by GE-Fanuc. </li></ul></ul></ul></ul><ul><ul><ul><ul><li>PROSAFE-RS Dual Redundant by Yokogawa </li></ul></ul></ul></ul><ul><ul><ul><ul><li>*Triple Modular Redundant </li></ul></ul></ul></ul>Built in Redundancy Externally Redundant MSc I&C, GCAL
  16. 16. TER ESD Replacement/Upgrade (3) Installation Space Required MSc I&C, GCAL
  17. 17. TER ESD Replacement/Upgrade (4) <ul><li>These were assessed using a weighting system & rating score (1-5), with the higher score being preferred. </li></ul>Technical Criteria & System Ratings MSc I&C, GCAL
  18. 18. MSc I&C, GCAL Systems Results Trusted Trusted would be most suitable system in terms of space requirements, obsolescence, fault tolerant and availability. Tricon Tricon can be suitable in terms of installation space but its size would be 2 times larger than Trusted and is less Fault tolerant. PROSAFE- RS Prosafe-RS can be suitable in terms of installation space but its size would be 2 times larger than Trusted. Although it is SIL3 rated and 99.999% availability but have double redundant architecture rather than TMR architecture Aadvance For 50 % capacity Aadvance will occupy than two system bays i.e. requires very large installation space. GMR GMR would occupy around three system bays and it can't be install in TER for 50% capacity.*1 For 20% still the space requirements are huge.
  19. 19. Summary <ul><li>The TER ESD/HIPS system is near capacity and cannot be guaranteed to be able to accommodate any modifications. </li></ul><ul><li>Redesign the existing output logic would not be useful because </li></ul><ul><ul><li>The Program logic voting gates are almost used completely. </li></ul></ul><ul><ul><li>There is no certainty of this method after detail FEED study. </li></ul></ul><ul><li>TER ESD Partial Expansion </li></ul><ul><ul><li>No additional physical space for expansion in TER </li></ul></ul><ul><ul><li>Due to distance limitations existing I/O logic couldn’t be relocated. </li></ul></ul><ul><li>To replace TER ESD with new system </li></ul><ul><ul><li>Trusted would be most viable system </li></ul></ul><ul><ul><li>Tricon and Prosafe-RS can be used but limited in performance as compare to Trusted. </li></ul></ul><ul><ul><li>Aadvance and GMR have very large installation space. </li></ul></ul>MSc I&C, GCAL
  20. 20. Conclusion MSc I&C, GCAL Techniques Recommendations ESD Replacement First choice Partial Expansion Not Recommend Redesign 2oo3 Relay voter logic Not Recommend TER ESD Expansion Not Recommend Safety Systems Recommendations Trusted First Choice Triconex Second Choice Prosafe-RS Third Choice Aadvance Not Recommend GMR Not Recommend
  21. 21. <ul><li>THANKS </li></ul>MSc I&C, GCAL