Daewoo Shipbuilding Marine Engineering (DSME) was established in 1978 at Okpo Bay, Geoje Island, on the south-eastern tip of the Korean Peninsula, and at that time was part of the company that also builds cars. In 2000, DSME became an independent company building a variety of marine vessels, offshore platforms, drilling rigs, and floating oil production units. In 2002 it generated US$7 billion in sales, providing marine transport and oil companies with products of unparalleled quality, and supporting them with cutting-edge IT and a staff whose expertise and dedication are respected around the world.

In November 2002, British Petroleum (BP) engaged DSME to build a new offshore drilling platform that would be located in Mexican Bay, North America. Although this was the first time BP had hired DSME, they had something in common — they both knew Rockwell Automation's products and services. As an OEM, DSME had used Rockwell Automation's Allen-Bradley PLCs, ControlLogix software, push buttons, as well as low voltage and medium voltage IntelliCenter Motor Control Centers (MCC) in their products since 2001. BP knew Rockwell Automation from their U.S.-based relationship and, when they awarded DSME with the US$400 million project, they specified Rockwell Automation as the preferred supplier for motor control and platform communications.

Challenge
Running an oil production facility on land is a complex undertaking; factor in the added challenges that inherently come with working in the middle of an ocean and operational difficulty is significantly increased.

The remote location is in itself problematic. If something fails, it takes more time to bring in replacement parts or systems and transport maintenance technicians to the site than it would for an on-land facility. Those logistics escalate repair and maintenance costs, and impact downtime. Simply said, if the rig is not pumping oil, it's losing money both in terms of production and customer satisfaction.

Consequently, a safe, highly reliable motor control system with high end communications was essential for BP, since that would minimize downtime and maintenance costs, and improve safety and customer satisfaction.

DSME also had to install the MCC into a tight space. To help make that easier, Rockwell Automation delivered the MCC, which is already a relatively compact unit, before the fully-outfitted control panel for the platform was installed.

BP set up another challenge for DSME, a monetary one: they negotiated a penalty for each day the project was late. The companies agreed that DSME would lose 0.9% (or US$3.6 million) of the total bid on the project for each day the project was not finished.

With the clock ticking, DSME began working toward the deadline.

Solution
With support from Rockwell Automation, Korea, and the Rockwell Automation team in Japan and United States, DSME built the platform in their GeoJeshi, Kyung Nam, Korea facility. Rockwell Automation's IntelliCENTER Medium Voltage and Low Voltage MCCs were installed into the platform's distributed control system (DCS), which means an integrated hardware, software and communication solution is in place. IntelliCENTER features pre-configured software that displays real-time data, trending, component history, wiring diagrams, user manuals and a spare parts inventory. The IntelliCENTER MCCs monitor and control virtually every motor on the platform.

To get the installed system up and running, engineers from Rockwell Automation's Global Manufacturing Solutions group handled commissioning. With its "plug-and-play" setup, IntelliCENTER reduces installation time and minimizes facility downtime. It is able to quickly start delivering intelligent diagnostic and predictive failure information.

Results
With a foundation integrating Rockwell Automation's IntelliCENTER MCCs, DSME delivered to BP a highly-reliable, stable control system for the Mexican Bay platform. Remote monitoring and diagnostics enabled by the digital communication capability provide real-time condition monitoring, and ensure quick response to failures while significantly improving maintenance conditions. As a matter of fact, the improvement in maintenance results in 30% savings on maintenance costs each year.

Simply stated, the system works better and is more cost-efficient than the old approach. The ability to more rapidly react to problems and superior troubleshooting minimizes downtime.

In addition, a single IntelliCENTER MCC unit can be serviced while all other units remain powered up. The combination results in higher production and, in turn, increased customer satisfaction. It also improves safety, both for the operators and the environment, since a more stable system, with a higher level of operational monitoring, is less likely to spill oil into the ocean.

The reduced wiring costs lowered the capital outlay for installation. And, when it comes time to add more motor controls, the modifications will be easy; IntelliCENTER is built to accommodate new units and is designed so that additional sections can be easily added to either end, accommodating the tight space requirements.

"We are very satisfied with Rockwell Automation's fast delivery and support, as well as the product quality," said B.S. Cho, engineering department manager. They are so happy that a second project is now being built.

Mr. Cho speaks of fast delivery, a critical element to the sale. Rockwell Automation's approach helped DSME keep their promised delivery date. DSME realized the most revenue that they could from the sale and BP began operations on schedule, which keeps their customers, and their stockholders happy.