abb kårstø projects summary rev 3

Statoil Kårstø SAS Upgrade ProjectsEng. Manager Andrew McConnell, ABB AS Process Automation Division

ABB Scope Overview

© ABB GroupMay 2, 2023 | Slide 2

Process and Stakeholders

Kårstø is a Gas Processing Plant located in Western Norway. This is the largest export harbour for LPG in Europe, and the 3rd largest in the world.The first part of the plant was put into operation in 1985.

Export Capacities:Salesgas / Dry gas:• Statpipe 28”: Capacity approx. 20MSm3/day• Europipe II, 42”: Capacity approx. 72 MSm3/day

NGL and Condensate:• Ethan: 112 tons/hour• Propane: 385 tons/hour• i-butan: 76 tons/hour• n-butane: 145 tons/hour• nafta: 106 tons/hour• condensate: 351 tons/hour

Introduction to Kårstø Gas Processing Plant


Process and Stakeholders

Gassco established in 2001, 100% owned by Norwegian Government.Neutral service provider to all North Sea Gas ProducersKårstø is operated by Statoil as Technical Service Provider

https://en.wikipedia.org/wiki/Gassco

InfrastructureOwnersGassled

Regulatory BodiesOD, Ptil, MD,DSB, etc

OperatorGassco

Technical Service ProviderStatoil

Gas Owners(consortium)


Project value, from customer perspective

The SAS Systems at Kårstø continually evolved since 1985. There are several distinct system architectures in use. The KEP2010 Project saw a major upgrade of the control systems,

approx 12,000 hardwired IO replaced. The KEP2010 Project also saw an entirely new PSD system split out. The existing (3rd party) ESD systems were replaced. The oldest parts of the F&G system was completely replaced Standard library and custom libraries were produced.

Hardware migration achieved signal-by-signal. Non-critical loops – Changeover during live operation Sub-Critical loops – live operation with compensatory measures Critical – Changeover during shutdown

Target was for maximum percentage of signals to be changed over pre-shutdown to minimise the risk of overrun.

KEP2010 SAS Upgrade - Some requirements and challenges


ABB project organisation

ABB O&G Bergen Engineering and supply of PCDA System Engineering and supply 800xA HMI Engineering and supply PSD System Engineering and supply of Network system extensions

ABB O&G Oslo Engineering and supply Fire & Gas System Engineering and supply of Simulator(s)

ABB O&G, Stord Develop 3rd party interfaces to 800xA (sub-supply to ABB Bergen). Engineering and supply of SAS upgrade for the NGL Project

ABB Engineering Center Bangalore, India: Sub- supplier to ABB Oslo and Bergen for HMI display development. Application programming for parts of Fire & Gas Application programming for parts of PCDA Supply of Engineering resources (STA) to Bergen, Oslo and Kårstø.

ABB RFF Trutnov, Czech Manufacturing of Cabinets for PCDA, PSD, and Fire & Gas

ABB Sweden 800xA Software and Hardware S800, AC800MHi, Support

ABB Minden, Germany Melody Hardware and Software, Composer, Support

PASYS Minden, Germany; Melody System Cabinets and power supplies

ABB locations involved in KEP2010 SAS Upgrade



In total 14 LER’s were affected by the Migration. Hardware deliveries:

95 Marshalling Cabinets refurbishments, consisting of S800 Remote I/O and terminals. Mounted, prewired and tested on frames ready for installation in existing cabinets.

12 Power Cabinets for field I/O. 10 S900 Remote I/O cabinets (for installation in Hazardous areas). 16 system cabinets with PM875 controllers, power and

communication modules. Software:

Develop and test a completely new function library according to NORSOK standard I-005.

Reconfigure all application software to comply with NORSOK standard I-005, based on new SCDs. Hence this is not a 1:1 conversion of application software.

Re-establish / Reconfigure all links to 3rd party systems. - typical CCC antisurge control and motor control centres.

Develop and test high speed antisurge algorithm for implementation of antisurge control in PCDA

KEP2010 PCDA Scope of Supply



2012 – 2013 Control Room Upgrade (EPC Scope) 2014 – 2016 HMI Upgrade (FEED Study => EPC Scope).

New Virtualised Server ParkNew Process SimulatorAsset Optimisation, Integrated Operations

Success factors: Focus on Value for money Precision in problem understanding and solving Knowledge of existing plant systems Early identification of shut down scope Timely execution Maintain safe Operability of the plant Maintain plant Regularity Minimise risk through use of Qualified technology Improved system Capacity and Lifetime

Continuing and increasing responsibility for ABB at Kårstø


Functional Design and early involvement

KEP2010 – participated as part of Integrated Team working for overall EPC Contractor

LSD – ABB had EPC Scope, but using existing FEED HMI Upgrade – ABB had full FEED and EPC (Extended Scope)

responsibility for Project execution

Program design standards

Hardware typicals

Cabinet layouts

Power distribution

Application guidelines

Tools and methods

Consistent and qualified project team driving progress

FEED EPC

Commissioning and startup

Installation supervision

SAT Loop check support SIS loop validation

suppor As-built

documentation

Site

Operations support System

maintenance Health checks Spares

management Training Life cycle support Obsolescense

management

O&M

Engineering, procurement, construction

Hardware build Application

configuration Model

development Testing and

acceptance FAT


45 Operator & Engineering Clients

45 Servers – All critical servers in redundant configuration

Diverse Locations

KEP2010 New Hardware

Existing

Control

Hardware

PCDA

PSDF&GESD (Hima-Sella)

HIPPS

Interface to existing (Safety) Systems


Managing technical interfacesChange Management


Migration strategies using existing real estate

• LER’s contain a mix of old and newer generation equipment.

• Suite of new controller cabinets was supplied

• Pre-mounted I/O “racks” are used to replace old IO System

• As an example for this LER:• 2 off controllers for the PCDA

(1 cabinet) and 2 off controllers for the UCP (1 cabinet) shall provide the necessary capacity to replace the 14 existing controller stations, and ensure that the required segregation between separate parts of the process trains should be maintained.

Typical PCDA upgrade of equipment room

Existing Melody

I.S. DORELAYS

20-ZC-100

20-ZC-100-CP0120-ZC-100-CP0220-ZC-100-CP0320-ZC-100-CP0420-ZC-100-CP0520-ZC-100-CP0620-ZC-100-CP0720-ZC-100-CP0820-ZC-100-CP09

Contronic P

HardwiredDevices J.B

800xAConnectivity

servers in93-ZC-100

KA-CSMEL3A/B

IS/NIS

O-Net

New ESD/HIPPS

HardwiredDevices J.B

IS/NISProfibus DP**

HW I/O*

HW I/O*

Field

Profibus DP**

HW I/O*

HW I/O

20-ZC-100-MC0120-ZC-100-MC0220-ZC-100-MC0320-ZC-100-MC0420-ZC-100-MC0520-ZC-100-MC0620-ZC-100-MC5120-ZC-100-MC5220-ZC-100-MC5320-ZC-100-MC54

20-ZC-100-DM0220-ZC-100-DM04

(incl. Bentley Nevada)

20-ZC-100-DM05

Local UCP

Electrical Room

HW I/O

HW I/O*

HW I/O*

HW I/O**

20-ZC-100-CP11

NOTE 3**

* To be deleted ** New Installation1.) Expand existing network switches for O-net2.) Existing Modbus links to Melody are not shown3.) New S800 I/O clusters for PCDA.4.) New Wago high speed I/O modules for antisurge5.) The H2O analyser will remain in 20-ZC-100-TC016.) Existing Melody controllers to be moved from KISL02 to KISL037.) Existing I.S. DO relays are mounted in ESD cabinets.

Notes:

20-ZC-100-DM0120-ZC-100-DM03

Local Panels

Note2&6

T100/200 CP-Bus *

I/O

I/O

MaestroUX

ContronicP and existing Melody

**

*

Profibus DP**

NOTE 4**

20-ZC-100-TC01

HW I/O*ESD

Planar4

Profibus DP

C-Net(C)

20-ZC-100-CP12

C051 & C052

20-ZC-100-CP13

C053 & C054

*

Existing Melody (F&G)

20-ZC-100-CP10

KISL03

KISL03

KISL03

Profibus DP

KISL03Note1&6

20-ZC-100-PC02

P01

New PSD

Note7

Note5


Migration strategies using existing real estate

• Mounting frames are Rittal sections. • 300 new knife terminals, (IS or Non-IS signal)• S800 remote I/O modules mounted on DIN rail • All cross wiring in the MC panels shall be marked

with to/from details on both sides of each wire.• Temporarily mount the assembled mounting frame

in the Marshalling cabinet.

• Field Cable Wiring input data from SPI• S800 IO allocation (with segregation)• Cross wiring info generated for Manufacture & Test• IO Info used for channel allocation (programing)• Data re-imported to SPI for as-built

Marshalling Cabinet mounting frame with S800


PSD System

The System cabinets contains the following main components: Redundant CPU-unitsI/O Cluster containing signal interface cards for hardwired signals including termination units.Exi barriersPower Supply and power distribution/fuse panel.Cables for connection between the PSD node cabinet and the existing field termination cabinet (MC). All components are labeled with a position and a equipment number. I.e. the cluster modem unit in the cabinet can be labeled +B1-T100. +B1 is the position in the cabinet and T100 is the equipment number.

PSD System Cabinet


Hardware Migration – Concept NEW PCDA Controller Cabinet

NEW PSD controller and S800 IO

New IS

Frame

in MC

New NIS

Frame

in MC

PCDA I/O

Profibus Links

PSD IO was hardwired to new PSD Cabinets

Mig

rate

IO w

ire b

y w

ireM

igra

te IO

wire

by

wire

Migration of HMI via ”Parallel Operation”, F&GMaestro Unix GraphicsLEVEL 2 Overview

800xA GraphicsLEVEL 2 Overview

Existing Melody Group Logic(eg 74UA101)

New Melody Logic Eg: Fire Area 2R400(Based on 74UA101)

New AC800 HW & Logic for (eg)Fire Area 2R400

Typical Åsgard Fire Area Hardware

Melody Detector Logic

Step 1:DetectorLogic clean-up(Naming rules)

Step 2: Copy Group Logic

Single Gas (DO)

MelodyConnect

SIL Relay

Single Fire (DO)SIL Relay

MAC (DO)SIL Relay

Single Gas (AI/DI)

Single Fire (AI/DI)

MAC (AI/DI)

Step 3: Rebuild Group Logicaccording to

KEP2010 CAP requirements

(seperate MAC)(Delete CP links)

Group signals to HMI:•Single Gas•Single Fire•Fault•Block

Gas/Fire/MACper Fire Area to CAP via AC800M

HW signals

Output DevicesBlue/Red lightsSounderCCR Alarm

Critical Action Panel

Transfer Outputsto new Group Logic

BL/TL/ISC (AI/DI) BL/TL/ISC (DO)SIL Relay

Escalation Area LogicFrom CAP via AC800M


Control Room UpgradeCCR was upgraded with new Furniture and 4 x Large Screen Displays

comprising a total of 42 x 60" Large Screen Cubes .


Current Project

Renewal of servers with virtualised system Significant reduction in number of servers and footprint Upgrade of 1875 Graphics and trends displays to PG2. New Process Simulator (entire plant is covered) Process Model updated and interfaced to emulator of all

plant control hardware. Simulator covers Process control, PSD, ESD, F&G Improved Asset Management Integrated Operations, Blocklog, PNSM, SEPTIC (Statoil

proprietary loop tuning software)3rd Party Metering Interfaces.

Cybersecurity to latest standards, whitelisting.

HMI Upgrade


Technical Highlights & Lessons Learned

Importance of defining job well in early stages Get maximum information from existing config data. Be wary of as-built information Understanding of Plant and any restrictions inherent in

systems - Find the limits. Cooperation between all parties leads to successful

execution Identify problems – bring out into open – solve at earliest

possible stage Try to use standard solutions to give best support and

avoid later costs.

abb kårstø projects summary rev 3

Documents