Petrobras FPU construction
Petrobras redundant processors

Petrobras, the Brazilian national oil company was formed in 1953. The vertically integrated company has grown to international status, with activities in 27 countries.  Petrobras has exceeded the 2 MMBBL/d production level and is ranked the 7th largest oil company in the world.

Offshore exploration yielded discovery off the coast of Rio de Janeiro in the Campos Basin. The Basin has proved to be rich in oil reserves with development of field such as Albacora, Marlim, Roncador and Barracuda-Caratinga. Of the 55 currently existing fields, 36 are considered mature, but with new technologies, production has increased. Today, oil production from these fields provides 100% of Brazil’s domestic oil consumption.

Petrobras has also been a leader in offshore technology. Some of the worlds largest platforms and floating production vessels, FPU & FPSO, are producing oil in the Campos Basin. P-53, a floating production unit (FPU), produces at the Marlin Leste field ,  120 km off the coast of Rio. P-53 is linked to 15 production wells and nine injection wells.  P-53 has the world’s largest rotating turret (where well pipes connect to the floating platform).  This arrangement allows the ship to rotate around the well pipes, so that it always faces the wind.  The power for the FPU is provided by four Rolls-Royce RB-211 power generation units, capable of delivering over 100 MW of power.  The two P-53 PG modules are named P-05A and P-05B.  These two modules provide power for the entire FPU.  The other PG modules provide power for two motor driven Dresser high pressure injection compressors and pumps driven via large electric motors with variable speed drives.

UCG was awarded the project in 2006.  The scope of supply included two Fire & Gas (F&G) detection systems for the power generation modules.  Details include:

  • Fully redundant PLC systems including processors, I/O, and communications.
  • Redundant instrumentation (field devices)
  • Seamless integration with the Rolls-Royce supplied Unit Control Panels.  This included full integration with the Rolls-Royce FT-210 HMI system.
  • Communications and interface with the Siemens control and visualization system (ECOS) for the entire FPU.
  • The panels are certified by BV (Bureau Veritas) and TUV Rhineland to meet the stringent safety requirements of the off-shore hazardous environment.
  • The systems were tested and certified to IEC 60079-2, including specialized inert gas purge and pressurization tests.

The systems were delivered to the fabrication yard in at Niteroi, Rio de Janeiro, and the commissioning of the systems commenced in Rio Grande del Sol, an ocean port in southern Brazil.  Final commissioning and testing was performed at sea in the South Atlantic Ocean.  The systems have been tested and approved, and are in full operation.