Yokogawa’s Integrated Solution Contributes to Reliable and Efficient Operation of Usan FPSO

Case Study by Yokogawa:  Total S. A. (Total) is a major oil and gas company with operations in more than 130 countries that span all aspects of the industry, including both upstream (exploration, development. and production) and downstream (refining, marketing, and the trading and shipping of petroleum products) operations. Total has been operating in Nigeria for 50 years and its deep-offshore oil & gas field development projects have been one of the main growth drivers in Africa. In Nigeria, the company operates through Total E&P Nigeria Limited (TEPNG) which carries out all upstream activities, including deep-offshore operations.

The Usan field is situated offshore Nigeria within oil mining lease (OML) 138, some 100 km south of Bonny Island, at a water depth of 750 m. Construction of the Usan FPSO by Hyundai Heavy Industries commenced in 2008 and was overseen by TEPNG. The vessel was launched in April 2011 and arrived at the field in July 2011. The Usan field came onstream in February 2012 and is able to yield 180,000 barrels of oil per day.

Usan FPSO specifications:

  • Hull dimensions: 320 m long x 61 m wide x 32 m high
  • Oil storage: 2 million barrels
  • Oil processing: 180,000 barrels/day
  • Oil-water separation: wash-tank inside the hull
  • Seawater injection: 190,000 barrels/day
  • Produced water treatment: 100,000 barrels/day
  • Gas compression: 5.2 million standard cubic meters/day
  • Topside dry gross weight: 25,000 tons
  • Hull dry gross weight: 87,000 tons
  • Living quarters: 130 people during normal operations (180 max.)

As the supplier of the integrated control and safety system (ICSS) for the Usan FPSO, Yokogawa Korea was involved from the early stages of this project. The delivered solutions include the CENTUM CS 3000 process control system (PCS) for the hull / topside control, the subsea control with the interface solution and overall control of wells and risers (OCWR), and the Plant Resource Manager (PRM) package for instrument management. These are integrated with third-party systems and software such as a process safety system, emergency shutdown system, fire and gas system, machine monitoring system, process data server, and operator training and maintenance system. Yokogawa’s vortex flowmeters were also installed in the field. From the very start of operations at this field, the entire facility has run safely and smoothly.

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