ABB's Integrated Solutions Drive Sustainable Operations on the BW Opal FPSO

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BW Opal sets sail to Australia; Source: BW Offshore

On May 28, 2025, the BW Opal officially set sail from Seatrium’s flagship Tuas Boulevard Yard in Singapore, marking a significant milestone in the Barossa project. This state-of-the-art floating production storage and offloading unit (FPSO), owned and operated by BW Offshore, is set to play a crucial role in producing gas from the Barossa field, located 300 kilometers offshore Darwin, Australia. ABB delivered key components including a massive E-House, Integrated Control and Safety Systems (ICSS), and advanced digital solutions, designed to ensure the FPSO operates efficiently and safely.

ABB's Integrated Solution: Core Technologies for Offshore Operations

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The BW Opal FPSO project demonstrates ABB's extensive capabilities in Process Automation and Electrification, enhancing the efficiency and operational excellence of complex offshore facilities. The project features several key components:

  1. 230MW E-House and Electrification: ABB provided a massive E-House and topside & hull electrification, powering one of the largest floating generation facilities on an FPSO. This robust solution ensures reliable energy supply for all operational needs.
  2. Integrated Control & Safety Systems (ICSS): ABB supplied a comprehensive ICSS, integrating power management (PMS) and HVAC control systems. This ensures centralized management, operational efficiency, and the highest standards of safety across the entire facility.
  3. Advanced Digital Solutions: The project includes a powerful digital suite featuring the first APM Predict on Edgenius, monitoring 1,088 assets, along with Process Simulators and IoT solutions. This enhances operational efficiency and predictive maintenance, enabling data-driven decisions and optimized performance.
  4. Comprehensive Engineering & Critical Systems: ABB's scope extended to critical engineering studies, and the delivery of essential systems such as High Voltage Partial Discharge (HVPD) monitoring, a robust Fire and Gas System (FGS), Emergency Off-Watch (EOW) capabilities, and advanced Subsea Control systems and interfaces. These systems are essential for maintaining safety and operational integrity throughout the FPSO's lifecycle.

Main data

Customer: BW Offshore
Site: Barossa is a large gas-condensate field located offshore in the Timor Sea, approximately 300 km north-northwest of Darwin, within the Australian Commonwealth Marine Area.
Customer need: Delivering one of the industry’s largest state-of-the-art gas FPSOs, with environmentally considerate design efforts and energy efficient technologies.
Scope:
  • Large E-House (31.5 m width X 24.4 m length, 50.8m)
  • Topside and hull electrification (230MW installed power)
  • Engineering studies for Optimisation
  • Partial discharge HVPD system
  • Complete ICSS with integrated PMS, HVAC control system
  • FGS system
  • Condition Monitoring System (CMS) – First APM Predict on Edgenius with 1088 assets
  • Process Simulators, IoTs, EOW
  • Subsea Control system and interface
  • ABB Alternators for GTG and STG
Application: Floating production storage and offloading
Customer benefits:
  • State-of-art FPSO design with advanced process control, increasing asset performance & reliability
  • CO₂ reduction with Combined-Cycle Power Generation Technology
  • Capex reduction & flawless execution with integrated electrical, automation, PMS, FGS, subsea control & E-House solution
  • Reduced operational costs & improved reliability with Asset Management & Partial Discharge Management System
  • Remote monitoring with a secure cyber network
Commissioning year: 2025

Navigating Challenges Through Collaboration and Innovation

The BW Opal FPSO project faced several challenges, including supply chain disruptions following COVID and the complexities of integrating advanced technologies into an already complex FPSO design. However, ABB's commitment to collaboration and innovation, working alongside partners like BW Offshore and Seatrium, enabled our teams to navigate these obstacles effectively. The successful integration of ABB's solutions into the BW Opal hull is a testament to the dedication and expertise of all teams involved.

Enabling Resilient and Efficient Energy Supply

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The BW Opal is now in Australia, with the project poised for production commencement. The BW Opal is expected to significantly contribute to global energy supplies. Uniquely designed with a strong focus on sustainability, the FPSO is engineered for up to 66% less energy consumption than industry standards and aims for a 15% reduction in power system GHG emissions2, thanks to carefully selected energy efficient technologies for the FPSO.

ABB's advanced electrification, automation, and digital solutions are crucial for realizing the FPSO's impressive efficiency and environmental targets. This project underscores ABB's commitment to supporting the evolving energy landscape by enabling precise control, intelligent power management, and real-time monitoring to drive operational excellence and greater sustainability in the offshore sector. The BW Opal FPSO is not just a vessel; it's a floating testament to the power of advanced technology in shaping the future of energy.

ABB Barossa E-House FPSO Project – M-40 Module

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