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The 2
nd
Generation DC All-Electric Subsea Production Control System
Daniel Abicht / Cameron; Jan van den Akker / Cameron
Copyright 2011, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 25May2011.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to
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Abstract
With the successful operation of the first All-Electric Production Control System
this technology continues to proven its advantages. With a system availability of
well above 99.9 % (status Dec, 2010), initial development targets have been
significantly exceeded. While this pilot system further continues to gain field
experience, the development of the 2nd generation DC All-Electric Subsea Production
Control System already is in its final stages.

A mature development initiative planting the design on the successful and field
proven CameronDC System has been initiated. Key target was a further
simplification of the system architecture and an implementation of a state of the
art fiber optics communication while maintaining commercial feasibility. As a
result the advantages of the DC All-Electric technology such as environmental
friendliness, improved reliability & availability and real time feedback are
combined with the advantage of a high speed communication using fiber optic in one
Production Control System concept. Naturally, relevant standards including API 17N
have been considered as part of this development initiative.

The 2nd generation DC All-Electric Subsea Production Control System represents
state of the art technology in several aspects. High voltage transmission enables
significant step-out distances. The available high bandwidth enables a transfer of
large data amounts even for complex field architectures. Functionalities to control
subsea actuators have been expanded. The already applied performance assessment
approach enabling incipient failure detection has been maintained.
Discussing the operational feedback as well the development targets this paper will
introduce the concept of the 2nd generation DC All-Electric Subsea Production
Control System and address its inherent advantages. The qualification strategy will
be outlined. It also will describe the experience gained during the development.


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2. List of Acronyms

AC: Alternating Current
CDU: Communication Distribution Unit
DC: Direct Current
DSL: Digital Subscriber Line
EH-Mux: Electro-Hydraulic Multiplex
EPCU: Electrical Power and Communication Unit
EPU Electric Power Unit
EFL: Electric Flying Lead
ESCM: Electric Subsea Control Module
ESCSSV: Electrical Surface Controlled Subsea Safety Valve
SEM: Subsea Electronic Module
SIIS: Subsea Instrumentation Interface Standardisation
FO: Fibre Optic
HMI: Human Machine Interface
HVCDU: High Voltage Communication and Distribution Unit
IP: Internet Protocol
IWIS: Intelligent Well Interface Standardisation
MCS: Master Control Station
PCB: Printed Circuit Board
PRCM: Power Regulation Control Module
ROV: Remote Operated Vehicle
TCP: Transmission Control Protocol (internet)

3. Introduction

The premises for the development of all electric technology are its clear advantages in comparison with electro-
hydraulic multiplexed systems. Compared with EH-Mux systems, electric actuation does not require hydraulic fluid,
providing benefits with respect to environmental friendliness. This is an aspect gaining more and more industry and
governmental attention, with an ultimate goal of achieving ZERO discharge systems. Another aspect of using electric
actuation is the improved control capabilities provided by the electric motors, as opposed to moving hydraulic fluid from
A to B. Electric motors can provide real time feedback, e.g. of the position and power consumption of the valve or choke
being operated. A further aspect is based on the experience that electronic components in general have much higher and
better predictable reliability figures than complex mechanical components consisting of a large quantity of moving parts
exposed to potentially dirty fluids. It is therefore anticipated that electric systems have much better reliability figures
than EH-Mux systems. By adding the full redundancy design, the inherent system availability is increased. This
perceived improvement on reliability and availability is currently being verified on various projects worldwide, and the
initial results are promising. Electric technology can also be seen as an enabler for ultra long offsets (removes the
problem of flocculation of static fluids), and ultra deep water (no need for subsea accumulation)

The first generation all electric control system Cameron developed consists of a master control station (MCS) with
standard HMI software installed, and two independent electrical power and communication units (EPCU) which provide
power and communication for subsea. Each subsea channel (A or B) has two subsea modules, all of which are
ROV/diver retrievable. The first module is the Power Regulation Control Module (PRCM) which regulates power and
demodulates incoming communication signal. The second module is the Electric Subsea Control Module (ESCM) which
controls X-Tree and manifold functions. More specifically and for each channel, the first module (PRCM) reduces and
regulates the 3kV DC input from topside to 300V DC and forwards the communication signal. The reduced voltage and
independent communication signal then goes to the second module (ESCM). The latter controls valve functions, logs
actuator parametric data, receives sensor information, and communicates with surface control equipment. A sketch of the
system concept is shown in figure 1.

To transport electric power, direct current (DC) was chosen, rather than alternating current (AC). This provides the
major advantage of minimizing energy losses which could prove important for long distance offsets. To deliver
equivalent electrical power, the required cable cross sectional area of a DC transmission line is smaller than that required
for an AC transmission line.

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Figure 1, System Concept of the 1
st
generation All Electric Technology


An important factor in the design of the electrical X-Tree system was the development of the fail safe close electrical
actuator by Cameron. This actuator consists of a drive motor and a clutch motor. The drive motor forces the valve
open against a closing spring. As soon as the valve is fully open, the drive motor stops and the clutch motor (electrically
activated wrap spring clutch) ensures that the valve remains open by means of a friction-based mechanism. In the open
position, the drive motor is completely unloaded. Only a small amount of power (less than 100 W) is required from the
clutch motor to hold the valve in the open position, which is the normal operating condition of the valve. If the electrical
supply is interrupted, the valve will return to the closed safe position by the closing spring. The fail safe close principle
of the actuators at power loss provides the safety requirement for well critical applications. The electrical choke valve is
a fail safe as-is. Upon loss of power, it will stay in last commended position using a rack pinion principle (Gerardin et
al. 2009). Derived from this basis, spin off technologies such as the Omni Choke have been developed and qualified
successfully (Abicht 2010a).



Figure 2, Cut-away model of an electrically actuated gate valve

MCS MCS MCS MCS
Rig
Power
Rig
Power
PRCM PRCM PRCM PRCM
A A A A
PRCM PRCM PRCM PRCM
B B B B
Anode Anode Anode Anode Anode Anode Anode Anode
eSCM eSCM eSCM eSCM
1A 1A 1A 1A
eSCM eSCM eSCM eSCM
1B 1B 1B 1B
Act 1
A B
Umbilical
Seawater
Return
Act 2
A B
Sensor
A B
Seawater
Return
EPCU EPCU EPCU EPCU
B B B B
EPCU EPCU EPCU EPCU
A A A A
Cathode Cathode Cathode Cathode Cathode Cathode Cathode Cathode
Anode Anode Anode Anode
Umbilical Umbilical Umbilical Umbilical
Anode Anode Anode Anode
Umbilical Umbilical Umbilical Umbilical
eSCM eSCM eSCM eSCM
2A 2A 2A 2A
eSCM eSCM eSCM eSCM
nA nA nA nA
eSCM eSCM eSCM eSCM
nB nB nB nB
eSCM eSCM eSCM eSCM
2B 2B 2B 2B
4
4. Performance of 1
st
Generation DC All-Electric Subsea Production Control System

The prototype system operating a field in the North Sea is producing since 6th September 2008, and since that date
has been operational. Initial results on availability and operability have been very promising. Based on available data up
to 15
th
Dec. 2010, approximately 19,920 hrs of possible operation have been recorded and an overall system availability
of above 99.9% has been achieved.

This value significantly exceeds expectations raised by the results of the RAM analysis as part of the development
effort. The mentioned analysis indicated an expectation that the DC electric subsea control system would provide a 2%
increase in system availability. Concerning the assessment of the installed K5F systems this was 95.5% vs a 93.3%
figure produced for an equivalent electro-hydraulic based system (Abicht 2010b). After a careful investigation of
operational data it was found that during the first six months of operation less than 2 hours downtime were attributed to
the all-electric control system. The undesired event occurring was a topside network failure and is not related to any
subsea system components. Thus, after this period an inherent production availability figure of 100% was produced.
Amongst others these results are well in line with supporting information provided via the performance assessment
system (Abicht et al. 2010). Although very promising for a prototype system, a thourough decision has been made to
take into account lessons learned and experiences to further advance this technology.

5. Limited features of existing Technology / Lessons learned

Since September 2008, more than 2-1/2 years of operational feedback has been collected, and various discussions
with operators took place on identifying requirements and constraints for further applications of electric control systems
technology. To increase the feasibility of the all electric technology for the most recent field developments and
applications hardware intensity needs to be reduced. This requires modifications to the current system set-up, without
compromising the unique reliability and availability design features introduced by the first generation.

Operational feedback confirmed that the option of having two individual ESCMs and corresponding mounting bases
on a Tree assembly is not preferred. The initial thought of this set-up was that if the ESCM on one channel failed the
other ESCM would continue to operate the Tree, whilst the failed ESCM would be retrieved. In an operational
environment a Tree is typically shut down while ROV or diver operations, hence this advantage is not fully utilized. A
single mounting base for a fully redundant ESCM will suffice. This approach will reduce hardware cost whilst still
maintaining the inherent system availability figures it was initially designed to do.

The first generation has full redundancy for each actuator and sensor. Detailed discussions with various operators
confirmed that this is not always required. Non-critical functions could be operated by via a single channel approach
from the ESCM. A new generation should therefore have the flexibility to combine full redundant with single channel
functionality in any desired configuration.

The electric system as deployed for K5F, is using a coaxial cable for transmission of power and superimposed
communication, using a proprietary communication protocol. Client feedback suggested Implementation of state of the
art technology provides the capability ble of transmitting at high bit rates, using open architecture communication
technology. For power transmission, twisted pair or quads cable technology is preferred.

The phase 1 installation on K5F consists of an EPCU, PRCM and ESCM for each channel, and for each tree. This
approach implies significant hardware to larger field developments consisting of 10 or more X-mas trees. With the phase
2 development on K5F, which is the addition of a third X-mas tree, the set-up can be modified in a way that one channel
can control up to 3 ESCMs maximum. However, for a classic 4-well drill center approach this would not be sufficent. In
that context the next generation would need to have an enhanced functionality.

6. Inclusion of state of the art communication technology

The ultimate target of introducing an open architecture communication network to an electric subsea controls systems
allows the evolution towards a plug and play installation. The communication network based on Ethernet and
transmission control protocol/internet protocol (TCP/IP) enables an expandable and flexible architecture as the nodes of
the subsea components behaves similar. The underwater equipment is addressed using IP addresses. This technology in
combination with the usage of optical fibres provides superior step out distances of 150 km (or more if repeaters are
used) with a bandwidth of 100MBit/s and more. Infield distribution can be made with direct copper Ethernet or by using
Ethernet range extenders like digital subscriber line (DSL). Also fiber optic infield distribution is possible. All these
technologies allow full flexibility and communication control (van den Akker 2010).

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The inclusion of this technology resolves several of the limiting features addressed in the previous paragraph. In
addition it also allows taking further advantage of the high volumes of data produced. The increased data transfer rate
can be used for improved control and also further enhances performance assessment and condition monitoring
capabilities something already in use for the first generation equipment.

The advantage of using this technology is that major and critical components are field proven on various subsea
projects using electro hydraulic multiplex control systems increasing the technical readiness level. This supports the
design and qualification process for the 2
nd
generation electric controls system.



Figure 3, Subsea Electronic Module (SEM) with inclusion of a fibre optic module and DSL boards

7. Concept 2
nd
Generation DC All- Electric Subsea Production Control System

The 2
nd
Generation DC All-Electric Subsea Production Control System represents another milestone in the evolution of
appropriate technology for complex subsea applications. The approach of this development can be described as integrated,
consisting of a combination of various tools and mechanisms.

Major development targets can briefly be summarized as follows:
- Highest inherent system availability over the entire design life
- Modular system set-up (implementation of functional reduncany where required)
- Increased functionality of single subsea modules
- Increased communication capability
- Reduction of system hardware
- Provision of standardized interfaces of third party equipment including ESCCV
- Maintainance of Performance Assessment and Condition Monitoring capabilities
- Maximum technical readiness level
- Consideration of obsolescence aspects
- Reduction of system target costs

Below picture describes the system concept of the 2
nd
generation DC all electric technology. This system consists of a master
control station (MCS, not shown in schematic) with standard HMI software installed, and two independent electric power
units (EPU) which provide power and communication for subsea. Each subsea channel (A or B) is connected to the HV
CDU. This first module converts the incoming fibre optics communication signal, e.g. to a DSL signal establishing a
communication to the Electric Subsea Control Module (ESCM). Further to that it regulates and converts power. Interfaces for
subsea instrumentation and third party equipment are considered and provided. Furthermore, a protection against short
circuits is implemented. This means that in the unlikely event of a short circuit of one of the subsequent modules, which in
addition are protected, all remaining trees are protected allowing a continuation of production for the remaining wells. It is
worth noting that amongst other this protection is resettable. Via seperate high voltage interfaces the two HVCDUs are
interconnected to up to five [5] ESCMs. This interface allows for a reduced cable cross section which leads to an additional
cost reduction.
6


Figure 4, Concept of the 2nd DC-All Electric Subsea Production Control System
The ESCM controls X-Tree and manifold functions. Depending on the modular set-up a single ESCM can control up to 32
electrical actuators. In a regular setting redundant power conversion units are implemented. Analog to classical Subsea
Control Modules utilized in electro-hydraulic production control systems the ESCM also consists of a redundant
communication section. Naturally, a protrection against short circuits is considered for all key components such as Power
Supplies, Motor Controllers, Modems, etc increasing component reliability and system availability. It also provides an
interface for tree instrumentation and third party equipment. Latest standard such as the SIIS and IWIS are considered. Of
special note is the logging function of this module. Next to data such as actuator parametrics sensor information and
diagnostic / housekeeping values, parameters of interest for subsequent system performance assessment and condition
monitoring are communicated to topside. Both, HVCDU and ESCM are ROV/diver retrievable. Component obsolescence
aspects have been considered for HVCDU and ESCM. The state of the component life cycle is observed via a dedicated
software tool.

Similar to the 1
st
generation the 2
nd
generation DC all electric subsea production control system is designed to enable long
step-outs for remote applications. Without repeater a distance of up to 160km can be reached from topside to subsea. The
maximum distance between the HVCDU and ESCM can be up to 15km, which is a major advantage, e.g. for the application
controlling manifold functions via a the X-tree.

To close the electrical circuit the seawater return consisting of a subsea anode and subsea cathode package remains as an
option. However, based on customer request and commercial feasibility a return path also can be established via the
umbilical.

Controls up to 5 ESCMs
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8. Qualification Approach

As the all electric system technology is still fairly new in the subsea completions arena a comprehensive and demanding
qualification program currently is in execution. Similar to the successfully applied approach for the 1
st
generation three levels
of qualification testing covering all components from the smallest electronic circuit board to large main assemblies are
considered being part of the qualification program. In line with ISO 13628-6, a bottom-up approach was applied as shown in
figure 5.


Figure 5, Qualification approach 2nd DC-All Electric Subsea Production Control System

Qualification tests are usually witnessed by third party.Testing begins on Printed Circuit Board (PCB) level (Q1 testing).
Once completed successfully, the next step is to test at sub-assembly level testing (Q2 testing). This already included
integration testing to ensure proper interface design. Once this level is completed with positive results it is followed by final
testing at assembly level which as well included testing and qualification of the entire interface structure. In some instances
guidelines within the standards are exceeded such as with electronic PCBs. Hyperbaric tests are in progress simulating 3,000
m water depth. Since all-electric production control is a rather new technology, some components are not covered by relevant
industry standards. Thus testing was performed according to a benchmark approach successfully utilized for the 1
st

generation. Having utilized this approach it is ensured that qualification testing exceeded basic testing requirements in both
quantity of tests and severity. The results of the qualification tests are properly documented in an overall qualification dossier
and the according design files.

Next to the qualification testing program the reliability ensurances as well as technical readiness were subject of special focus
as part of the development initiative. Mission critical electronic components have carefully been choosen based on functional,
reliability and obsolescence criteria. Further to that MTBF values have been estimated using advanced methods. On system
level a RAM analysis is in execution already showing promising results. For both assemblies and the entire system FMECAs
have been performed. HALT testing currently is in planning phase. A review of the technical readiness of key system
components has been conducted under consideration of API 17N.


9. Summary

Considering the successful operational feedback of the 1
st
generation along with its unique technical capabilities, the 2nd
generation DC All-Electric Subsea Production Control System represents state of the art technology in several aspects. High
voltage transmission enables significant step-out distances. The available high bandwidth enables a transfer of large data
amounts even for complex field architectures. An open architecture for communication is implemented. Ethernet and DSL
can be used for high bandwidth and long step-out distances on the one hand and on the other hand this technology enables
expandable and flexible subsea installations. Functionalities to control subsea trees and actuators have been expanded. The
already applied performance assessment approach enabling incipient failure detection has been maintained. Next to reliability
and system availability aspects component obsolescence ones have been considered as part of the development. A thorough
qualification program is in execution.

The 2nd Generation DC All-Electric Subsea Production Control System represents another milestone in the continuous
improvement and technical advancements of subsea technology

Fault Current Control
Qualification Program
Modem Qualification
Program
Power Supply
Qualification Program
Motor Control
Qualification Program
Comms Qualification
Program
Fuse Qualification
Program
Power Supply
Converter
Qualification Program
ESCM Qualification
Program
HVCDU Qualification
Program
System Qualification
Program
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10. References

Abicht, D. 2010a DC Electric Standalone Choke. Paper SPE-133441-MS presented at the the SPE Production and Operations
Conference and Exhibition Tunis, Tunisia, 810 June 2010.

Abicht, D. 2010b All Electric System Performance Assessment. Paper presented at the SUT Subsea Control and Data
Aquisition International Conference, Newcastle, UK, 2-3 June 2010

Abicht, D. and Braehler, J. 2010 Performance Assessment of the DC All-Electric Subsea Production Control System. Paper
SPE-133439-PP presented at the Asia Pacific Oil & Gas Conference and Exhibition held in Brisbane, Queensland, Australia,
1820 October 2010

Gerardin, P., MacKenzie, R. and van den Akker, J. 2009 The First All Electric Subsea System on Stream: Development,
Operational Feedback and Benefits for Future Applications. Paper SPE 124290 presented at the SPE Offshore Europe Oil &
Gas Conference & Exhibition, Aberdeen, UK, , 811 September 2009.

Van den Akker, J. and Voelkel T. 2010 Robust and versatile Control systems to meet the challenging artic conditions. Paper
SPE 136377 presented at the SPE Russian Oil & Gas Technical Conference and Exhibition, Moscow, Russia, 2628 October
2010.
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