System evaluation life extension programme

  • Client Operator
  • Year 2019
  • Business unit Multidiscipline

Apollo won a competitive tender to perform a large life-extension project for an operator based in the North Sea. The project equated to 70,000 people hours over 2 years.

As part of that life-extension case study was an opportunity to look at each section of the FPSO individually in order to extend the life of the asset. Within that required a large controls systems review.

An independent review was completed on 18 control systems across the asset, asking the following questions:

  • Is the control system obsolete?
  • Are sufficient spares available to maintain the system for the next 5 years?
  • Will the failure of the system have an immediate Production, Safety or Environmental impact?
  • Are there any reliability concerns?

The problem:

The client was concerned about an ageing asset but still could see reservoir returns and so wanted to extend the current life expectancy of their FPSO.

In order to do so, it is vital that the assets control systems are sufficiently supported, reliable and available in line with reforecast CoP dates.

The solution:

The solution was to fully review all the systems and make cases for upgrade or retention.

Due to this review, it would mean that the system was expected to operate beyond 2030. It also meant that the operator was able to save significant CAPEX costs.

By conducting an in-depth review it enabled us to advise our client with regards where they should target their investment in support of the extended operation. where they should invest their money. This was done by reviewing each system independently, identifying the system components, performing a reliability review, vulnerability review, highlighting the impact of a failure and providing options for life extension.

And for all you engineers who want more details:

The Problem

Initially, when our E&I team looked at the project there were 18 systems reviewed and obsolescence status made and cases for upgrade or retention made for the asset to operate beyond 2030. These systems are as follows:

  1. Compressor Controls
  2. PCS – Allen Bradley
  3. Cranes Control
  4. Nitrogen Generator
  5. Power Management System
  6. Inert Gas
  7. Telemetry System
  8. Boiler Control
  9. HV Switchgear
  10. Stern Offloading
  11. PCS Experion
  12. Turbine Controls
  13. Fire pump Controls
  14. Nucleonic Level Profiler System
  15. LV Switchgear Controls
  16. PAGA
  17. Emergency Intercom
  18. CCTV

The current supported life of each system needed to be understood, and a proposal for life extension beyond 2030 was to be recommended.

The Solution

A system reliability assessment was carried out that with operations engagement, that covered the following areas:

  • failure mode identification
  • spares availability and holdings
  • vulnerability and impact of failure
  • options to support life extension to close off production
  • cost and schedule estimates

The Outcome

Apollo was able to deliver a reduction in overall CAPEX costs by only recommending system upgrades that were entirely necessary. In addition, Apollo was able to provide a more targeted plan in support of life extension. This provided the client with a better understanding of the offshore implementation and enabled them to make informed strategic decisions to ensure reliable operations beyond 2030

Client Benefit

  • The client was given an independent recommendation per system reviewed
  • Apollo looked at the whole asset and assessed due to priority – this way the operator could prioritise critical system upgrades in support of the extended operations program
  • We also established an annual testing program (used/ refurbished spares)
  • Recommendations were prioritised based on safety and impact to operations
  • Appreciation of system cost and schedule requirements

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