The BONGA project

Invensys Systems (UK) Ltd are in the process of delivering the Shell Bonga Floating, Production, Storage and Offloading vessel (FPSO) project. On completion of the project the FPSO will be commissioned to produce 225,000 barrels of oil a day plus gas from a deep-water field 100km off the Nigerian coast. Oil production will be transferred from the onboard storage tanks to tankers and the gas to an offshore gas-gathering pipeline for eventual liquefaction at the Bonny Island LNG Plant. The production facilities on the vessel (topsides) comprise of 22000 tonnes of power and process modules linked to the sub sea wells by steel risers attached to the sides of the vessel.
		Invensys Systems (UK) Ltd is the Main Control Vendor (MCV) for the Topsides Contractor AMEC Services Ltd. Invensys is responsible for the design, development, build and installation of the Process Safety and Control System (PSCS) and central control room suite. In addition Invensys is integrating the control systems of the various topsides sub-vendors and all the systems within the hull of the Bonga vessel.
For the past 12 months a combined team of Invensys, AMEC and Shell engineers have been located at Invensys, Crawley, UK offices focussed on the delivery of the various aspects of the project. The PSCS comprises, principally, of five systems: Foxboro I/A Series Distributed Control System (DCS) – process control and monitoring Foxboro I/A Series Safeguarding and Shutdown System (SSDS) – process shutdown and trips Triconex Emergency Support System (ESS) – fire and gas safety system Management Information System (MIS) – OSI PI and SAP R3 implementation and Local Area Network (LAN) Asset Management System (AMS) – smart field devices networked to centralised master station
		Extensive use has been made of fibre optic communications to connect the field equipment to local equipment rooms. The PSCS incorporates many new high speed (Ethernet) interfaces to sub-vendor packages and also utilises OPC technology in the link between the sub sea control unit and the DCS.
In addition to the PSCS, Invensys is providing a high fidelity training simulator (BTS). The BTS scope includes the development and integration of the hydrocarbon and utilities models.
The BTS uses virtual stimulation provided by a suite of software products from Invensys. The great advantage of the virtual stimulation approach being that the BTS can incorporate the very latest configuration data from the PSCS without the need for hardware changes. In addition, the BTS is now being used for an enhanced FAT and providing pre-commissioning support to the sites teams; ensuring that then the PSCS configurations reach the Bonga they will be capable of safely operating the production system.The BTS scope also includes training of the Shell trainers who will in turn train the FPSO operators. Provision of the BTS in parallel with the PSCS also provides opportunities for early process development and system testing.
Invensys is providing a range of project services including full project management, front-end engineering, system configuration, software loading, system integration, site installation, commissioning, loop tuning and on-going support.