Alarm management
Alarm philosophy, rationalisation, performance benchmarking, and advanced alarm handling techniques.
Process Control
Oil Export Control Optimisation
Targeted controller tuning and optimisation restored stable oil export operation after changing field conditions introduced instability in the main oil line pump control system.
The Challenge
Export stability was drifting
For a major UK oil and gas operator, process conditions at an offshore installation had evolved significantly over the field's operating life and were expected to continue changing until end of production.
Variations in flow rates, pressure conditions, and fluid characteristics had introduced instabilities in the main oil line pump control system, creating challenges in maintaining smooth operation and efficient throughput.
To restore stability and improve operability, new control valves with reduced capacity were installed to better match current and future production profiles.
ICSS was engaged to support the operations team during plant restart, providing specialist control engineering expertise to tune controllers, optimise the system, and validate performance of the main oil line pump control system.
Our Scope
Tuning matched to real conditions
ICSS was responsible for ensuring that the upgraded control system delivered stable, responsive, and efficient operation across all expected operating conditions.
Our team verified that the replacement control valves provided stable and responsive control for current production rates and process conditions, then retuned and optimised control loops to accommodate a range of likely future production scenarios.
The work included tuning and optimisation of the pump suction vessel level controller, pump minimum flow controller, export pressure controller, and pump recycle cooler temperature controller.
Our engineers worked closely with site operations and control room personnel throughout the restart to ensure all adjustments were aligned with production, safety, and equipment protection requirements.
The Result
Stable control, lower operator burden
Through targeted tuning, optimisation, and close collaboration with site personnel, the project delivered a reliable and responsive control system that significantly improved operability, efficiency, and production stability.
The work ensured the main oil line pumps could be operated confidently under automatic control, reducing manual workload and supporting consistent performance throughout the remainder of the field's life.
All controllers were successfully retuned and operated under fully automatic control, ensuring smooth and stable process behaviour.
The new control valves and optimised control schemes delivered improved process stability, reduced operator intervention, and enhanced protection of critical rotating equipment.
Process Control
Unlocking potential. Turning stability into value.
Our solutions are targeted, measurable, and impactful. Whether we are working on routine optimisation or resolving chronic control issues, we deliver tangible improvements to stability, operability, and bottom-line performance.
Tuning and optimisation
Control strategies, loop tuning, debottlenecking, stabilisation, and emission improvement programmes.
Start Here
Need help with process control performance or optimisation?
Tell us what you are trying to stabilise, tune, or optimise across greenfield projects, brownfield upgrades, or late-life assets. We will help shape the scope, de-risk the decision, and define a practical route to measurable performance improvement.