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Case Studies > Global Oil Producer Leverages Real-World Models to Help Deploy Offshore Control System in Record Time

Global Oil Producer Leverages Real-World Models to Help Deploy Offshore Control System in Record Time

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Applicable Industries

Oil & Gas

Applicable Functions

Process Manufacturing

Use Cases

Predictive Maintenance
Process Control & Optimization

Services

Data Science Services

The Challenge

Genesis Consulting was approached by one of the top 25 global independent oil producers to develop a redeployment strategy for its Floating Production Storage and Offloading (FPSO) unit Global Producer III. The offshore deployment of the FPSO presented a number of challenges due to deeper waters, distant locations, smaller oil fields, and the complexity and unpredictable consequences of offshore deployment. It was costly, logistically challenging and often hazardous, typically requiring a highly skilled team of engineers to make several trips offshore to achieve first oil. Genesis knew that the best way to overcome these obstacles was to test and commission the FPSO — especially its new process control system — while the unit was still in dry dock.

About The Customer

Genesis Consulting is a leading consultancy and engineering company that serves a large number of clients in the upstream oil & gas process industries. With over 300 in-house engineers and scientists, Genesis provides high-quality engineering support primarily to the UK offshore market. The company has established partnerships with global solution providers such as AspenTech. Recently, Genesis was approached by one of the top 25 global independent oil producers to develop a redeployment strategy for its Floating Production Storage and Offloading (FPSO) unit Global Producer III.

The Solution

Genesis recommended an integrated AspenTech modeling solution to replicate real-world conditions and variables, ensuring the timely and successful completion of the project. A fully representative model of the new compression trains was designed using Aspen HYSYS. This model was then linked to and controlled by the systems of the Global Producer III. The integration of the controls system could be taken off the project’s critical path and resolved independently and at faster speeds, resulting in an early and seamless deployment. Once the dynamic model built in Aspen HYSYS was connected to the FPSO’s controls system, Genesis uncovered major bugs in the PCS, PSD and ESD hardware and was able to diagnose and correct all issues before startup to reduce project uncertainty and risk.

Operational Impact

The integration of the controls system was taken off the project’s critical path and resolved independently and at faster speeds, resulting in an early and seamless deployment.
All problem resolution took place in dry dock, avoiding the expense and logistics of multiple trips to an offshore facility.
Following the success of the Global Producer III project, the client asked Genesis to create a similar model for a training facility located onshore. This model will assist with operator training by presenting various scenarios that demand risk mitigation.

Quantitative Benefit