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2628 08 Production Control Systems PDF
2628 08 Production Control Systems PDF
August 2015
DNV GL 2015
2013
August 2015
Module structure
Section 1 Introduction to control
systems
Introduction
Basic instrumentation
Advanced instrumentation
Section 5 Instrumentation
Introduction
Commonly used terms
Methods of control
Choice of system
Communication systems
Umbilicals
Infield connections
Multi-bore connectors
Jumpers
Connectors and Penetrators
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Learning objectives
By the end of this module you will be able to understand.
What a subsea control system comprises
What factors influence control system design
How a subsea control system relates to other systems
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Communications
Software
Mechanical
Electrical
Subsea production
control system
Instrumentation
Interfaces
Fibre optics
Hydraulic
To name a few.
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Initiator
Logic
Actuator
Automatic
Manual
Automatic
Pneumatic
Hydraulic
Manual
Hydraulic
Electrical
Pneumatic
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Process
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Initiator
Logic
Actuator
Process
Sensor
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Initiator
Logic
Actuator
Process
Sensor
Sensor
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Power
Power
Power
Initiator
Logic
Actuator
Sensor
Process
Power
Sensor
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Introduction
What is the definition of a subsea control system?
ISO 13628-6 says..
control system operating a subsea production system during operation
More useful.
To safely maintain the flow of hydrocarbons from a subsea facility
What are the main challenges for a subsea control system?
What are a subsea control systems two primary requirements?
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Supply
Return to
tank
Solenoid
Function
Supply
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- Fail closed
Fail open
- Fail as is
Hydraulic accumulator
Pressure vessel used to store
hydraulic fluid under pressure
Latched function
A function where the control signal
does not need to be continuously
applied.
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Methods of control
Direct Hydraulic
Platform
Umbilical
Valve
- Best suited to shallow
water
- Slow to respond
- Large umbilical
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Methods of control
Piloted Hydraulic
Platform
Tree
Umbilical
- Subsea accumulation
- Mechanical or electrical pilot
valve operation
- Valve sequencing can be used
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Valve
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Methods of control
Direct Electro Hydraulic
Platform
Tree
Umbilical
- Smaller umbilical
- Faster response
- Simplified control pod
Valve
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Methods of control
Electro Hydraulic Multiplexed
SCM
MCS
SCU
Platform
-
Umbilical
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Tree
Valve
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Methods of control
All Electric
MCS
SCM
SCU
Platform
Tree
Umbilical
Valve
- Complex electro-mechanical
devices
- Power electronic devices subsea
- High voltage distribution systems
- Harder to control failure modes
- Greater level of technical support
- Higher Intervention costs?
- Installation costs?
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Choice of system
System
Type
Cost
Maintenance /reliability
Flexibility
Step
out
Depth
Direct
Hydraulic
Low
Limited
Short
Shallow
Piloted
Hydraulic
Low
Limited
Short
Shallow
Direct
Electric
Low
Increased complexity.
Limited
Short
Shallow
Electro
Hydraulic
Multiplex
High
Expandable
Long
Deep
All Electric
High
Expandable
Very
Long
Ultra Deep
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Surface
components
Umbilicals (Hydraulic,
Electrical Power and Fibre
Optic)
Distribution
Subsurface
component
s
Instrumentat
ion
Connection systems
(Hydraulic, Electrical Power
and Fibre Optic)
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Surface equipment
Typical surface components can include:
-
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AKS EPU
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AKS HPU
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Bennex umbilical
terminations
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FMC MCS
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Subsurface equipment
Typical systems components can include:
- Umbilical Termination Assembly (UTA)
- Subsea Distribution Assembly (SDA)
- Subsea Distribution Unit (SDU)
- Communications Interface Unit (CIU)
- Subsea Electrical Junction Box
- Subsea Control Module (SCM)
- Subsea Electronics Module (SEM)
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Retrievable
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AKS SEM
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Copper or fibre
Pros
Fibre
Copper
Pros
High speed
Gigabits of information
Video and audio
Noise immune
Light weight
Sophisticated diagnostic tools
Cheaper modems
Easier terminations
Simpler connectors
Cons
Cons
More fragile
Harder to terminate
More elaborate connectors, especially
subsea
Expensive transmit and receive
equipment
Heavier umbilical
More expensive umbilical
Susceptible to noise
Lower data rates
Shorter distance
Ideally fibre optics should be used for all systems, however for simple shallow
water applications it may be harder to justify.
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Infield connections
Multi-bore connectors
Jumpers
Hydraulic
Optical fibre
Electrical
Couplers
Connectors
Penetrators
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Multi-bore connectors
Used to make the in field
connections from the UTA to the
SDAs and SDUs
Electrical connections
Fluid connections
Hydraulic control
Chemical
Fibre optics
Production flowlines
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Jumpers
Used to distribute electrical, optical and
hydraulic signals and supplies
Oil filled pressure compensated hose
Terminated with either a wet mateable
connector, coupler or penetrator
ROV installable
Can be used to reconfigure the system
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Couplers
ROV or diver operable, quick
release style connector
Wet mateable poppet
mechanism seals on release
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Electrical connectors
Wet and dry mate subsea
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Wet mateable
ROV or diver operable
Limited number of mates and demates
Fine tolerance
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Penetrators
Fibre optic or power (very high
voltages)
More reliable than connectors
Made up dry and they are not
serviceable subsea
Usually used to terminate one end
of a power cable
Bennex penetrator assembly
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Section 5 Instrumentation
Introduction
Basic instrumentation
Advanced instrumentation
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Instrumentation
The subsea control system will generally include the following:
Subsea and downhole transducers measuring temperature, pressure, valve
position, sand production, multiphase flow, well parameters and the condition of
the subsea control system equipment
Control system variables and housekeeping parameters such as hydraulic fluid
pressures, communications status and system voltages are also recorded for
analysis at the surface
Other parameters which can be monitored include :
Corrosion
Vibration
Strain
Movement (riser monitoring)
Ocean Current (riser monitoring)
In a modern system almost any variable in the control system can be made
available to the Process Control System
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Instrumentation - basic
Temperature (TT)
Pressure (PT)
The pressure and temperature transmitters can be
combined into a single instrument called a PTT
Both temperature transmitters (TT) and Pressure
transmitters (PT) can be used to monitor either the
process or the control system.
Sand
Intrusive type measures the erosion on a probe
inserted into the process flow
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Instrumentation - advanced
Corrosion
Intrusive sensors penetrating the process
flow, usually at the well head
Non-intrusive, normally fabricated as a
section of pipeline
Hydrocarbon
Cormon corrosion
sensors
Capacitive sensor
Flow meters
Normally mounted in-line
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Electrical
Power Unit
Master Control
Station
Hydraulic
Power Unit
Chemical
Injection Unit
TUTU
Umbilical
Termination
In-field Umbilical
(Hydraulic,
Electrical Power
and Fibre Optic)
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Subsea
Distribution
Subsea Control
Module
Electrical and
hydraulic
jumpers
Christmas Tree
Electrical
Downhole
jumpers
hydraulic hard
piping
Background courtesy of STATOILHYDRO AS
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Future developments
All electric field
Sub-ice operations
Increased sophistication of subsea processing units
Faster, more complex control loops
Increased instrumentation (process and condition monitoring)
Remote and integrated operations
Greater use of information
E-field systems
Increased Complexity
Harder to test
Increased attention to software quality systems, security and systems integration
TickIT, CMMI
Requirements engineering
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Key takeaways:
Safe operation
Availability
Simple and robust
Electro-hydraulic
All electric
Increased amount of information
Obsolescence
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