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In
1999, Emerson Process Management, Hydrocarbon and Energy Industry
Center, was awarded the front-end engineering design (FEED)
contract to develop and install the control, instrumentation,
and safety systems for the Esso Exploration Angola (Block 15)
Kizomba A project. In 2001, Emerson Process Management was awarded
the post-FEED contract for the lump sum turnkey (LSTK) portion
of Kizomba A, and approximately one year later, Emerson Process
Management was awarded a similar contract for the Kizomba B
project. Esso Exploration Angola (Block 15) is a subsidiary
of ExxonMobil.
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| The
Project Challenge |
| The world-class
Kizomba A and B projects of Angola’s Block 15 are part of the
largest deepwater development offshore west Africa. The Kizomba A
and B facilities were each designed to recover approximately one billion
barrels of oil (gross). They are located approximately 145 km offshore
and west of Soya, Angola.The first production from Kizomba A began
in August, 2004; today, the facility produces 205,000 barrels per
day of oil. The Hungo and Chocalho fields will be developed using
more than 30 subsea producing wells. This project will consist of
a floating production, storage, and offloading (FPSO) vessel and surface
wellhead platform (SWHP), both of which will be installed in approximately
4,000 feet of water. The offloading facility will consist of a catenary
anchor-leg moored (CALM) offloading buoy for transferring processed
crude from the FPSO to shuttle tankers.Kizomba B, the second hub development,
is expected to start in early 2006. This project will develop the
Kissanje and the Dikanza fields. The similarity and successful development
concept of Kizomba A will lead the development of Kizomba B.Esso requires
integration of the following key project elements: |
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•FPSO |
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•SWHP
and related facilities |
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•CALM
offloading buoy |
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•subsea
production systems with interconnecting umbilicals, risers, and flow
lines |
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The
Solution |
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Emerson Process
Management will lead the control and safety system detailed design,
engineering services, procurement integration, testing, startup, and
commissioning activities. There will be more than 35 third-party device
interfaces, some of which will use redundant object linking and embedding
for process controls (OPCs). Our team of over 100 experienced personnel
will perform a multitude of services, including consulting, project
management, engineering, drafting, administration, document management,
procurement, equipment assembly, installation, configuration testing,
and training. The first part of this project expended over 108 thousand
person-hours in a 12-month period.The project facilities will be operated
and controlled from an integrated control and safety system (ICSS)
that will be comprised of the following key components:
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•process
control system (PCS)—This will control and monitor all operations
of the facilities from a fully manned, centralized control room (CCR)
on the FPSO. The PCS that was selected for this project is a Fisher-Rosemount
DeltaV™ distributed control system (DCS).
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•safety
systems—A safety instrumented system (SIS), which will operate
independently of the PCS, will protect equipment and personnel from
process upset and emergency conditions, fire, and the unexpected release
of hazardous hydrocarbon vapors. The safety system programmable logic
controller (PLC) that was selected for this project is a Triconex
Tricon. The SIS will be tied to the PCS for monitoring and control
via a redundant OPC link. |
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•unit control
panels (UCP)—In addition to the remote control and monitoring
functions of the CCR, some major equipment will be provided with its
own standalone local panels. These panels will provide local control
during normal operation and assist operations personnel during equipment
startup and system troubleshooting. |
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The
Process |
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This project will be leveraged by Emerson
Process Management’s expertise in asset management, consulting,
and engineering services. Emerson Process Management will serve as
the main instrumentation and controls contractor (MICC); under the
MICC process, Emerson Process Management will work as the single-solution
provider and be assigned total instrumentation and control responsibility.
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Project
Benefits |
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The MICC business
model will mitigate the traditional instrumentation and electrical
(I&E) problems and delays that are commonly associated with large
projects. The MICC approach will enable partnerships between our customers
and the engineering, procurement, and construction (EPC) companies.
These partnerships will improve quality and provide cost-effective
solutions. This approach will minimize changes in scope and schedule,
which will reduce the potential for costs to grow. Our streamlined
management and engineering processes, together with standardized configuration
tools, will ensure significant cost-savings benefits to our customer.
The Kizomba A and B projects are key examples of how the MICC process
ensures that benefits and synergies are shared between projects.
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