Process Performance Start-up Services

During start-up of new builds one needs to adapt the process controls to the real-world setting. This includes setting PID tuning parameters, timers, ramp rates, pulse durations, filter times etc. In addition, specific control structures may not work in practice, and these will have to be re-designed, implemented and put into operation.


Typically there is a large amount of issues that appears when equipment or systems are to be operated for the first time.

For initial operation of the equipment and systems, many disciplines and roles are involved, and the activities are on the critical line of the start-up schedule.

This means that all issues will directly affect the overall progress negatively and give waiting time for disciplines not involved in fixing the issues.

The core of our Process Performance start-up service is our competency in bridging the gap between functional requirements and how these translate into programmable logic.


We will align with start-up timeline and prepare for starting up the different systems, focusing on control challenges that are frequently causing issues during initial start-ups and operation.

To perform such work efficiently we have established checklists, tools, and libraries of working control solutions.

This means that any redesign that is required, will be done by picking working solutions from our library, rather than ad-hoc redesign combined with a conventional trial and error approach which is often the result when a quick-fix is required.

References and customer statements

Teekay Knarr – Process Performance Start-up Services

ABB Process Performance was responsible for adapting the process controls to the real world setting, by tuning of the control logic parameters and control structures.

During the start-up phase, the team had one position on-site reporting to the start-up lead supported by an off-site team

After the main start-up milestones were reached, the mode of support moved to being off-site based with sporadic on-site trips

Results

Customer Concluding Statement 

“We were very satisfied with the Process Performance Start-up Services provided by ABB. Onsite support during the most hectic start-up phase was very helpful and timesaving. The services from ABB was a central part of our successful ontime achievement of the first oil milestone. In retrospect, we see that we should have involved the ABB experts earlier to transfer work load from onsite to onshore.”

                                                 
                                                Ketil Hox Start-up manager – Petrojarl Knarr FPSO, Teekay Petrojarl Production AS

Shell Ormen Lange – Process Performance Start-up Services

ABB Process Performance was responsible for adapting the process controls to the real world setting, by tuning of the control logic parameters and control structures.

During the start-up phase, the team had one position on-site reporting to the start-up lead supported by an off-site team

After the main start-up milestones were reached, the mode of support moved to being off-site based with sporadic on-site trips

Results

  • Estimated 3% increased production first year in operation

Customer Statement


“With the expertise of ABB’s Integrated Operations team, it was easier to identify problems early and to solve them permanently”
                               
                                        Arne Røsdal, operations support supervisor for Ormen Lange, Norske Shell

“There is no doubt about the enormous usefulness of ABB’s tuning team when starting up the plant. They were one of the keys to the success,”
 
                                      Per Sælevik, startup leader of Ormen Lange at Norske Shell

Process Control commissioning at Ormen Lange

Other References

  • Customer confidential 1: Uptime increase: oil train 64.5 h, gas train 135 h. Flaring reduced with 540 000 Sm3, causing the same amount of increased gas export.

  • Customer confidential 2: Uptime increase: oil and gas train 44 h. Flaring reduced with 1 800 000 Sm3, causing the same amount of increased gas export.

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