Energy | Ula MP

Extending life of obsolete control systems: Ula MP

Mitigating system obsolescence on the Ula field with strategic MP200 controller upgrades, extending operational life and ensuring safe, cost-efficient production.

As production assets in the Ula field continue to age, system obsolescence posed a significant risk to operational integrity. The outdated MP200 controllers, some over 20 years old, threatened unplanned shutdowns due to limited spare parts.

 

Init’s strategic upgrade approach helped extend the life of the control systems – ensuring safe, uninterrupted production well into 2025 and beyond.

Aspiration

Addressing obsolescence to prevent unplanned shutdowns

The Ula field’s control system, composed of three different generations of controllers (MP200, AC400, and 800xA), had become outdated, with the MP200 controllers obsolete since 2009.

 

 

A failure in these aging controllers could lead to lengthy, unplanned shutdowns, compromising both safety and production. The challenge was to find a cost-efficient and reliable solution that would mitigate the risks of obsolescence and ensure the long-term operation of the field.

Solution

Strategic system upgrade for long-term reliability

Init conducted a comprehensive FEED (Front End Engineering Design) study to identify the most effective solution to address the obsolescence issues. The recommended strategy involved upgrading the MP200/1 controllers to AC400-based versions, extending the system’s lifetime and reducing offshore testing requirements by reusing existing I/O. Init’s responsibilities and deliveries included:

 

 

  • FEED Study and Recommendations: Conducted a thorough feasibility study and presented the safest, most cost-effective upgrade options.
  • EPCI (Engineering, Procurement, Construction, and Installation) Delivery: Upgraded 7 MP200 nodes to Advant400 nodes.
  • Replacement of Obsolete Equipment: Replaced outdated S400 Remote IO units with modern, supported S800 IO units.
  • HMI System Update: Updated the 800xA Human-Machine Interface (HMI) system to ensure seamless integration and operation.

Upgrading Control and Safety Systems are always challenging. Init delivered this job on time and below budget with no impact to operations. Impressive!

Ella Kaliszuk, BP Ula/Tambar Area Operations Manager

Result

Extended system life and improved operational safety

Init’s solution extended the operational life of the Ula field’s control system to 2025 and beyond. By upgrading obsolete controllers and ensuring the reuse of key components, the project minimised risks, reduced the need for extensive offshore testing, and maintained safe, uninterrupted production.

 

 

The strategic upgrades ensured long-term reliability while controlling costs and mitigating the risk of unplanned shutdowns.

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