Typically, commissioning activities for a floating production, storage and transfer unit (FPSO) follow steps defined in the project schedule. Therefore, as all parties involved know, the beginning of some activities depends on the completion of others, a cycle that continues until the end of work on the site.
As usual, acceptance tests of automation systems are started after the integration and completion of previous activities, such as lifting and installing production plant modules on the platform, launching and interconnecting instrumentation cables , interconnection and fusion of optical fibers, certification of communication networks, availability of the electrical system to power equipment, among others.
Often, the need to wait for the completion of these stages makes testing and commissioning of automation systems become bottlenecksfor the completion of general activities, impacting the operation phase and offshore production.
Considering this information, Altus has been using the anticipation methodology for field acceptance tests of automation systems. With this, it is possible to release the automation panels to start the Loop Test, which is the validation of the complete loop between the instrument installed in the process plant connected to the programmable controller and checking the respective quantities and animations on the supervisory system screens.
To do this, a Test Jig is used containing a hardware architecture similar to the platform's original architecture. virtualization resources are used for the supervision system, enabling the reproduction of servers and operating screens. Acceptance tests for automation equipment and Loop Tests can then be carried out individually, per module of the production plant, and in parallel with previous activities.
When all predecessor activities to the automation system are completed, the Loop Tests will already be validated, enabling the prioritization of process plant simulation tests, interlocking logic tests and cause and effect matrix tests. This saves more time for validationand real verificationof all elements in an integrated manner. Furthermore, the unit's operation team has greater contact with the complete systems that will be used during the operation and production phase.
This methodology brings benefits to the client as it is possible to anticipate routine problems encountered during this stage of commissioning, without the deadlines defined in the schedule being affected. The procedure also enables more advanced validations, verifications and tests of the systems in a reality much closer to the unit's operational phase.
Recently, Altus used these concepts in the commissioning of an FPSO at the COOEC shipyard, in China, completed in December 2019. This procedure has also been applied in the commissioning of an FPSO at the EJA shipyard , in Brazil.
About the author
Fernando Andriola began his career at Altus in 2005, as a technical intern in the Engineering area. Since then, he has been developing his career in the sector, working on Oil & Gas projects, such as the commissioning of Petrobras oil platforms installed in the Brazilian pre-salt. Today, he holds the position of Interface Coordinator
