Enhancing FPSO Control Systems: A Dynamic Simulation and Virtual Commissioning Approach
Jordi Badía, Sergio Juan Calzado, Andrés Vega, José Marı́a Nougués · Offshore Technology Conference · 2024
Abstract In the domain of Floating Production, Storage, and Offloading (FPSO) facilities, the growing complexity of process configuration and control poses challenged in the Integrated Control and Safety Systems (ICSS) development. Traditional testing practices, such as ICSS Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT), are supplemented by the use of dynamic simulation for virtual commissioning. This paper explores the integration of a Distributed Control System (DCS) with a process simulator model, as an innovative solution to address common challenges in FPSO design and operation. The synergistic benefits include risk mitigation, optimized control logic, realistic scenario testing, reduced downtime, and validation of control system performance. Virtual commissioning enables early ICSS debugging and verification of operating procedures, and it proves particularly relevant in the offshore oil and gas operations of FPSOs, enhancing safety, efficiency, and operational effectiveness. Two case studies demonstrate the benefits of virtual commissioning in expediting and optimizing startup processes in greenfield project one if FPSO other in comparison the benefits of the first start-up of a chemical process.