Digital automation solution enhances oil recovery in Caspian Sea

The AMS Suite APM software is being used as part of Emerson's digital automation solution for the Chirag Oil Project offshore Azerbaijan. (Image courtesy of Emerson Process Management)

The Chirag Oil Project is the next major step in the ongoing development of the Azeri-Chirag-Guneshli field, the largest oil field in the Azerbaijan sector of the Caspian Sea. The multi-billion-dollar project, which was sanctioned in March 2010, is planned to increase oil production and recovery through a new offshore facility designed to expand field infrastructure between the existing Deepwater Gunashli (DWG) and Chirag-1 platforms.

Toward this end, the Azerbaijan International Operating Co. (AIOC), a consortium led by BP, has contracted Emerson Process Management to automate the new offshore platform. The company is expected to provide the automation and safety systems, asset management tools, and a broad range of measurement instruments to help operate the platform safely and efficiently. Emerson also will act as the Main Automation Contractor for the project, responsible for delivering project management services to ensure all equipment is properly installed and integrated to meet technical, budget, and schedule requirements.

Support for the Chirag Oil Project is being provided by the company's recently expanded base in Baku. Emerson has been represented in Azerbaijan since 1997, but the new office increases the range of project management and support services to the region and will play a critical role in this oil recovery project.

Project workscope

The company worked closely with BP for 18 months as part of the integrated FEED team to define a digital automation solution to meet the project needs. Emerson's PlantWeb digital plant architecture – including Foundation fieldbus communications, digital automation systems, asset management software, and intelligent field devices – will provide process control and access to management information. Its network of intelligent transmitters and valve positioners also will deliver continuous process and equipment health information to identify potential problems before they affect operations. These predictive capabilities also will help to deliver high platform uptime.

As part of the PlantWeb architecture, the DeltaV digital automation system for process control and DeltaV SIS process safety system for process shutdown and fire-and-gas monitoring will enable secure control of oil production on the platform. Additionally, AMS Suite predictive maintenance software will provide online access to instrument and valve diagnostics and automatic documentation of field device maintenance information – all contributing to ongoing efficiency of platform operations and maintenance activities. The AMS Suite: Asset Performance Management, based on Meridium's APM software, features a unified interface to assess asset health and criticality, optimize maintenance expenditure, and view key performance indicators of asset performance that help guide maintenance decision-making. Asset Performance Management also allows performance comparisons of key assets at other locations.

Emerson is delivering a range of solutions to monitor and preserve the efficiency of operation. For example, Roxar corrosion monitoring equipment can be used to monitor the internal condition of pipes, verify their integrity, optimize corrosion mitigation, and support inspection planning and planned asset maintenance. And a nonintrusive acoustic sand monitoring system also can provide efficient monitoring of sand production at the field. Additional Roxar intrusive systems will give direct information about the erosion effect of produced sand. Corrosion and sand erosion data will be integrated within an online system, enabling data management and reporting.

A range of measurement instrumentation including Rosemount level, pressure, and temperature transmitters will be installed throughout the platform. Advanced integrated diagnostics will help to identify potential problems before they cause a disruption to production. For example, Emerson's Rosemount guided wave radar transmitters will be deployed to monitor levels within inlet separators and scrubbers. These devices incorporate advanced diagnostics that help to identify any build-up on probes that can potentially cause problems. Early warning enables maintenance to be scheduled to minimize disruption.

The company's Micro Motion mass flowmeters are to be deployed for critical chemical injection measurement applications at the field. Under-injection of inhibitor chemicals can lead to mechanical problems, while over-injection can increase costs and adversely affects downstream fluid characteristics. Coriolis mass flow measurements, meanwhile, will provide the highest levels of accuracy and reliability.

TopWorx Valvetop Discrete Valve Controllers will deliver control and position indication feedback for pneumatically actuated ball isolation valves, and Foundation fieldbus communications will enable seamless interface between the automated isolating valves and the integrated control systems.

Commissioning and support

With Emerson responsible for all automation engineering and acceptance testing and for supporting BP with commissioning, configuration, and startup services, the Chirag Oil Project is set to deliver additional hydrocarbons to secure energy in a key region of the world. BP has estimated potential ultimate recovery from the supergiant field at more than 5 Bbbl of oil.

The commissioning will initially take place onshore Baku, including all loop checkouts and loop tests before the final offshore hook-up, and the AMS Suite will be used to streamline device configuration, commissioning, and system validation, helping to ensure the project meets its tight deadline.

Construction of the AIOC-operated project is scheduled for completion in 2013 to be followed by first oil. After startup, the local Emerson team will provide ongoing support services to the BP consortium, with the company's engineers based permanently on the platform for an initial period to provide complete support for the control and asset management systems, plant networks, and instrumentation. Additional onshore support will be provided, and this will continue throughout the lifetime of the project.