K Controls has used its expertise in sub-sea ingress protection and hazardous area approvals to develop 007-100 valve position monitors that will be used in a new floating, production, storage and offloading vessel (FPSO) being built for BP by Hyundai Heavy Industries in Korea.
The new FPSO will replace the existing Schiehallion FPSO that has been moored in 400m of water, 281km (175 miles) west of the Shetland Isles in the UK, producing oil from the Schiehallion and Loyal fields since 1998.
The reservoir sits 2000m below the seabed, covering an area of approximately 194sq km (75sq miles.) As a result of further exploration and technological developments during the past 20 years, recoverable reserves are now known to be more than double the original estimates. The Quad 204 project will also include an extension of the existing subsea system with a number of new wells. The FPSO and its subsea structures will be producing by 2017.
A total of 147 valve position monitors have been supplied for use on hydraulically actuated ball and butterfly valves. The valves will be used in the sea water ballast tanks that are used for vessel stabilisation. K Controls worked closely with the engineers at the Offshore Design & Engineering Division of Hyundai Heavy Industries in Korea, in order to arrive at an exact specification.
The majority of the position monitors contain end of travel reed proximity switches and some provide a 4-20mA with HART signal to monitor the position of modulating control valves or the opening and closing characteristics of critical isolating valves. Klearvision visual indicators were specified for certain applications. The 007-100 enclosures have been investment cast from a high-alloy austenitic stainless steel developed for use in seawater and other aggressive chloride-bearing media. They have been independently tested by SGS Baseefa to IP68, for submersion at a depth of 30 metres.
When not submerged, the position monitors could be in an area where hazardous gasses are present. They are therefore ATEX and IECEx intrinsically safe certified II 2 G Ex ia IIC T6. All the units have been supplied with multi pin connectors and the associated cable sets that meet the exacting standards required for both subsea and shipboard use. Each cable set has been cut to a predefined length between 19 and 166 metres in order to facilitate installation. Mounting kits for the actuators were supplied in Super Duplex stainless steel.
These products are also available with INMETRO hazardous area certification for similar projects in Brazil.
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