Topsides Engineering by Modular Simulation Models

Abstract

Abstract In recent years as the offshore industry strives for alternate ways to lower price and increase project efficiency, topsides are often designed and built based on modular design due to the compact process layout, lack of personnel accessibility for site fabrication and also similarity in design of process units involved in most of offshore projects. The modularization process requires a robust simulation model that can quickly perform screening exercises at early stages of the project and be able to validate the detail design from module sub-contractors as the project progresses. This article presents the application and benefits of a modularized, off-the-shelf dynamic simulation tool to support the modular design of an offshore platform during the whole lifecycle of the project, from conceptual design (Pre-FEED), to Front End Engineering (FEED), to EPC, to commissioning and start-up and to post-start-up (normal operation). Modular-off-the-shelf dynamic simulation tools will support the modular design of the offshore project by modeling each individual modular section of the plant using standard off-the-shelf template models that have been built to meet project requirements. The off-the-shelf models can also be replaced with customized models according to modular design of the plant and based on the data available at each phase of the project. The dynamic simulation tool has supported various projects for life cycle analysis, for verification of design, testing and verification of control strategy, for operation support during start-up, and troubleshooting and debottlenecking of operation of the plant with proven cost savings. This methodology was originally developed for installations in the United States and later was adopted for the design and engineering in other part of the world. In this article, case studies will be presented as well as the benefit achieved in the application of the modular simulation tools for topsides engineering. Based on the project scope, the modular simulation domain may vary from a single compression module to an entire topside facility for any floater with modular design such as an FPSO, semi or FLNG, associated wells and flowlines as well as linkage to third party software.