Modern DCS Achieves Flexibility, Safety, Security Far from Shore
Working with a system integrator, LLOG designed and implemented the new Delta House offshore FPS using a one-size-fits-most approach. Due to the accelerated timeline and the optimistic outlook for similar projects in the future, the company decided to design an FPS that would fit most offshore Gulf of Mexico locations, versus building it specific to one location. This decision helped speed design and implementation time, and also allowed for a flexible FPS design that could be easily repeated elsewhere.
The company chose to implement a modern, virtualized PlantPAx® DCS from Rockwell Automation. The virtualized system improved reliability and expandability with built-in disaster recovery and the ease of provisioning new hardware when needed in hours versus days or weeks. Additionally, because the PlantPAx system is built on open communication protocols, it provided LLOG with a scalable approach that could easily integrate with various OEM process skids deployed across the topsides processing equipment.
“Our existing Who Dat FPS is running on physical servers. In order to expand, we need to add and integrate another full physical server, a costly and time-consuming process,” said Fowler. “With a virtualized PlantPAx system on the Delta House FPS, we can easily expand and add another virtual server in minutes, and at no cost.”
As part of the PlantPAx system, LLOG has expanded visualization into its process control operations. Leveraging the Rockwell Automation software suite for production intelligence, the system allows operators to easily capture historical data for tracking trends, monitor the process, and collect and report key data, alarms and events to help make more informed operational and business decisions. The system uses updated grayscale graphics, making it easier for operators to see issues and rationalize alarms.
The system also allows LLOG to centralize authentication and access control by verifying the identity of each user who attempt to access it. Direct communication through the software allows the system to either grant or deny user requests for increased, built-in security. Additionally, using embedded Cisco technology, Allen-Bradley® Stratix® switches helped LLOG ease network configuration, management and support. Enhanced security features of the switches support system-wide security as part of a defense-in-depth approach.
Optimistic Future for Delta House
LLOG completed the full Delta House construction, including the DCS design and implementation and extracted first oil in an outstanding three years.
Not only was the timeline and FPS build extraordinary, but process system results since implementation have been equally momentous.
“The PlantPAx system has helped us realize increased uptime,” said Fowler. “In the first year using the system, we averaged an industry-leading 99 percent uptime on the new Delta House FPS.”
Since first oil extraction in April 2015, the facility has already produced over 60 million barrels of oil equivalents. From inception, the breakeven price for the development was $27 per barrel of oil. Going forward, the breakeven price is below $20.
The features of the PlantPAx system have also helped the company save valuable time and money. “When the FPS has an issue, the system is designed to safely shut down operations,” said Fowler. “Recently following a nuisance shut-in, with improved reporting and insight into system trends, we were able to get production back up and running in hours, minimizing downtime.”
The expandability of the controls system is unmatched. The Delta House FPS began operations with just a few wells. After a year and a half in production, LLOG has been able to simply add new wells as needed. Wells are typically miles away from the FPS, but through PlantPAx standardization, ease of integration and virtualization, incorporating new wells into the controls system is a painless process.
At the 2017 Offshore Technology Conference, LLOG was awarded the Distinguished Achievement Award for Companies, Organizations and Institutions in recognition of the Delta House project. The Delta House project was also named one of the top five projects in the world according to Offshore magazine.
Today, the Delta House FSP is processing from five fields versus just the three known at the time of construction. By the end of 2018, an additional three fields will be producing.
The results mentioned above are specific to LLOG’s use of Rockwell Automation products and services in conjunction with other products. Specific results may vary for other customers.
Allen-Bradley, PlantPAx and Stratix are trademarks of Rockwell Automation Inc.
