A global oil and gas company is using offshore technology expertise developed on the Norwegian Continental Shelf and applying these state-of-the-art processes to its Brazilian oil fields. The company is able to produce over 90,000 barrels of oil a day, and has reserves of 300- 600 million barrels from the Campos basin. ABB has played an important role in helping company managers maintain these production goals, and is providing local resources to help maintain production levels.
On a global level, ABB is engaged with the company in a joint industry project to develop power and automation for offshore factories. The five-year program is centered on the development of technologies required to power and control large-scale offshore pumping and gas-compression projects. Offshore pumping and gas compression contributes to improved utilization of oil and gas resources through greater recovery rates, reduced production costs and the further development of subsea production.
The ABB solution for the FPSO and wellhead platforms distributes power for the entire production process, including the electric submersible pumps in the production wells below the seabed. For the oil to flow between the platforms and the FPSO, it is heated in the flow lines. The two wellhead platforms transfer the produced liquids from the wells to the FPSO, moored in the middle. There are 30 horizontal production wells and seven water injection wells, which are connected to two drilling and wellhead platforms located about 10 kilometers (6 miles) apart. The platforms are connected to a FPSO with flowlines and power umbilicals. ABB supplies a multisystem automation solution, including field instrumentation and telecommunications systems. The solution includes a process control system, power management system, production information management system, fire and gas system, and emergency shut-down system.
The FPSO’s system is operated from an ABB System 800xA Extended Operator Workplace (EOW-x) control room onboard the FPSO. EOW-x offers an ergonomic operator environment that facilitates operator decision-making and produces measurable improvements in plant productivity, safety, information flow, and operator job satisfaction. Some 14,000 integrated operations on the vessel and platforms are controlled by ABB AC 800M process controllers and AC 800M high-integrity controllers.
The solution also includes an 800xA Simulator, which contains adapted versions of all the site automation systems and connects them to a dynamic process flow model. The simulator provides realistic and safe process simulation for operator training. It enables engineering, testing, startup, optimization studies, and upgrading to be performed and mastered in the simulator prior to execution in the field.
Thousands of hours of work are performed each year for the company by over 200 ABB specialists at remote centers worldwide, thereby reducing the need for this customer to deploy its own expertise at the sites. If an incident occurs, ABB has all the required skills to work on a solution immediately and implement it remotely.