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OIL & GAS

Introduction to Subsea Production

Systems
08 Production Control Systems

August 2015

DNV GL 2015
2013 August 2015 SAFER, SMARTER, GREENER

Module structure

Section 1 Introduction to control Section 5 Instrumentation

systems Introduction
Scope of control systems engineering Basic instrumentation
Basic control systems Advanced instrumentation
Section 2 Subsea control systems Section 6 Topside Control Systems
Introduction
Offshore control systems
Commonly used terms
Methods of control Where does it all fit in?
Choice of system
Section 3 Control system
components
Surface components
Subsurface components
Section 4 Connection systems
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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Section 1 Introduction to control systems

Scope of control systems engineering

Basic control systems

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Scope of control systems engineering

Communications

Software Electrical

Subsea production
Mechanical Instrumentation
control system

Interfaces Fibre optics

Hydraulic
To name a few.

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Open loop control

Initiator Logic Actuator Process

Automatic Automatic Hydraulic

Manual Pneumatic Electrical
Hydraulic Pneumatic
Manual

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Closed loop control Actuator feedback

Initiator Logic Actuator Process

Sensor

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Closed loop control Process feedback

Initiator Logic Actuator Process

Sensor

Sensor

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Powering the system

Power

Power

Power
Initiator Logic Actuator Process

The power supply can

be: Sensor Power
Hydraulic
Electrical
Pneumatic

Sensor

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Section 2 Subsea control systems

Introduction
Commonly used terms
Methods of control
Choice of system

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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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Subsea control systems

Does a control system fulfil its primary requirements?

Safe operation
2003 HSE Report into valve failures that resulted in a hydrocarbon release
showed:
43% of failures were from inadequate design, materials, etc
0% from control systems
Availability
2003 HSE Report into valve failures that resulted in downtime showed:
43% of failures were from inadequate design, materials, etc
24% of failures were from the control system
The cost per failure?
Average of 100 hours downtime

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Commonly used terms

Closed hydraulic circuit

Hydraulic fluid is returned to its point
of supply
Supply Function
Open hydraulic circuit
Hydraulic fluid is vented to sea or a Return to
tank
recoverable subsea storage vessel
Directional control valve or valve
Controls the flow of hydraulic fluid
Solenoid Supply Function
Electrical coil that controls the position
of a control valve
Vent to
sea

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Commonly used terms

Fail safe
- Fail closed Fail open
Returns to a safe condition in a fault
condition, can be fail open, fail close
or fail as is.
Usually controlled by a mechanical - Fail as is
spring
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

Low tech solution
- Best suited to shallow
High level of reliability water
Easy to understand - Slow to respond
Easy to fault find - Large umbilical
Easy to service
Cheap

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Methods of control

Piloted Hydraulic

Platform Umbilical Tree Valve

- Subsea accumulation - Not suited for ultra-deep
- Mechanical or electrical pilot water or long step outs
valve operation - Slow to respond
- Valve sequencing can be used - Large umbilical

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Methods of control

Direct Electro Hydraulic

Platform Umbilical Tree Valve

- Smaller umbilical - Not suited for ultra-deep

- Faster response water or long step outs
- Simplified control pod - Increased number of subsea
electrical connections
- Requires separate electrical
umbilical or multicore
umbilical

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Methods of control

Electro Hydraulic Multiplexed

SCM

MCS SCU

Platform Umbilical Tree Valve

- Long step out and deep water - Increased number of subsea

- Faster response electrical connections
- Simplified umbilical - Higher voltage connections
- Capable of complex control - More complex subsea
- Improved surveillance components
- More difficult to support

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Methods of control

All Electric

MCS SCU SCM

Platform Umbilical Tree Valve

- Ultra deep water and extremely long - Complex electro-mechanical

step outs devices
- Zero emissions - Power electronic devices subsea
- Suitable for harsh environments - High voltage distribution systems
- Subsea processing - Harder to control failure modes
- Easily expandable - Greater level of technical support
- More autonomous? - Higher Intervention costs?
- Lower operating and maintenance - Installation costs?
costs?

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Choice of system

System Cost Maintenance /reliability Flexibility Step Depth

Type out

Direct Low Low technical threshold. Limited Short Shallow

Hydraulic Most components topside.

Piloted Low Low technical threshold. Limited Short Shallow

Hydraulic Most components topside.

Direct Low Increased complexity. Limited Short Shallow

Electric

Electro High More complex, subsea Expandable Long Deep

Hydraulic equipment.
Multiplex
All Electric High More complex, subsea Expandable Very Ultra Deep
equipment. Long

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Section 3 Control system components

Surface components
Subsurface components

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Control system components

Surface
components

Umbilicals (Hydraulic,
Electrical Power and Fibre
Optic)

Distribution

Subsurface
Instrumentat
component
ion
s

Connection systems
(Hydraulic, Electrical Power
and Fibre Optic) Background courtesy of STATOILHYDRO AS

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Surface equipment

Typical surface components can include:

- Topside Umbilical Termination Unit (TUTU)
- Hydraulic Power Unit (HPU)
- Electrical Power Unit (EPU)
- Subsea Control Unit (SCU)
- Master Control Station (MCS)

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Subsea control unit

AKS SCU
Can act as a stand-alone control
station or integrated in to the PCS
Interfaces to subsea equipment,
HPU, EPU
Provides operator and engineer
access to the system
Acts as a gateway for third party
equipment
Expandable

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Electrical power unit

Semi-conductor based power supply system

Variable voltage output
Can house the communication on power
modem
Provides monitoring of the umbilical system.
Under and over voltage protection
Over current protection
Line insulation monitoring
Communicates to the SCU
For Subsea to Shore developments this can
be replaced by a high voltage transmission
system comprising a high voltage step-up
surface transformer connected by subsea
distribution umbilicals to subsea high voltage
stepdown transformers.
AKS EPU

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Hydraulic power unit

FMC HPU
Self contained unit provides high
and low pressure hydraulic
supplies for the subsea controls
(sometimes HP hydraulics is
derived from LP supply subsea)
Provides surface accumulation
Redundant motor pump sets
PLC monitoring and control
Interfaced to the SCU

AKS HPU

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Topside umbilical termination unit

Hydraulic, electrical and fibre optic

termination
Electrical terminations in internal
junction boxes
Individual block and bleed valves
for each hydraulic line
Individual pressure gauge per
hydraulic line

Bennex umbilical
terminations

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Master control station

Operator and Engineering access

to the system FMC MCS
HMI graphical interface to the
system
Stand-alone system or
Integrated into the distributed
control system (DCS)
Remote repeater stations
Can be local or remote

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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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Subsea termination assembly

Terminates and distributes the

umbilical
Electrical, hydraulic and chemical
distribution
Multi-bore connectors
ROV mateable jumpers
Configurable arrangement using
crossover caps and or jumpers

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Subsea distribution assembly /unit

Similar to UTA
In-field distribution of hydraulic
and electrical supplies and
communication signals
Subsea electrical junction box
Local transformation of power
supplies (step down
transformers)
Fibre to copper converters (CIU)

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Subsea control module

AKS SCM
Can be installed on SDUs, SDAs,
PLEM and XTs
Controls and monitors subsea
instrumentation and actuators
(valves, etc)
The SCM normally consist of:
Hydraulic and electric operated valves
Subsea Electronic Module
Couplers for electrical cables and
hydraulic lines.
Valves contained in an oil filled pressure
compensated housing
SEM in a one atmosphere pressure
vessel
FMC MKIV SCM
Retrievable
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Subsea electronics module

One atmosphere pressure vessel

Cards for control signal handling
and communications
Supports various communication
protocols
Power supplies for instrumentation
and actuators
Intelligent, able to perform local
control AKS SEM

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Section 4 Connection systems

Copper or fibre
Umbilicals
Infield connections
Multi-bore connectors
Jumpers
Connectors and Penetrators

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Copper or fibre
Fibre Copper
Pros Pros
High speed Cheaper modems
Gigabits of information Easier terminations
Video and audio Simpler connectors
Noise immune
Light weight
Sophisticated diagnostic tools
Cons
Cons Heavier umbilical
More fragile
More expensive umbilical
Harder to terminate
Susceptible to noise
More elaborate connectors, especially
Lower data rates
subsea
Shorter distance
Expensive transmit and receive
equipment

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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Direct hydraulic umbilicals

Older design
Large cross section
Lots of hydraulic lines (one per
function)
Limited electrical connections
Difficult to handle and terminate

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Multiplexed electro-hydraulic umbilicals

Smaller cross section

Steel tubes
Common hydraulic supply
Chemical injection lines
Fibre optic and copper signal
conductors
Power conductors

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Infield connections

Multi-bore connectors
Jumpers
Hydraulic
FMC MKIV SCM
Optical fibre with connections
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

FMC multi-bore connectors (collet type)

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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

ODI electrical jumpers

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Couplers

ROV or diver operable, quick

release style connector
Wet mateable poppet
mechanism seals on release

Ifokus Engineering quick

release couplers

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Electrical connectors

Wet and dry mate subsea ODI electrical connectors

Low voltage for signal
High voltage for power supplies
12KV Tyrihans
36KV Ormen Lange
Can be very problematic

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Fibre optic connectors

ODI electro optical
Wet mateable hybrid connector
ROV or diver operable
Limited number of mates and de-
mates
Fine tolerance

ODI optical connector

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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
Can be used as a barrier between
oil and water, gas and oil and gas
and water

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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
Read Matre WEPS PT
inserted into the process flow
Non-intrusive are based on acoustic devices
Valve position
Continuous measurement by LVDT or similar
Discrete measurement by proximity switch
Inferred from other measurements Cormon intrusive erosion sensor

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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
Capacitive sensor sensors
Flow meters
Normally mounted in-line
Multiphase flow meters
In-line ROV retrievable devices
Measuring the fractions of gas, oil and
water in the process stream.
Older subsea systems were not very
accurate (~20%), newer systems more
complex promise better results
Also measure, density, salinity, mass and
volumetric flow rate, pressure and Solartron ISA flow meter
temperature
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Section 6 Topside control systems

Offshore control systems

Where does it all fit in?

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Offshore control system

Platform /Process Control System

DCS System
Safety Systems
Fire and Gas System
Process Shutdown System (PSD)
Emergency Shutdown System (ESD)
Subsea Production Control System

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Where does it all fit in?

Process Control
System

Electrical Master Control Hydraulic Chemical

Power Unit Station Power Unit Injection Unit

TUTU

Subsea Umbilical (Hydraulic,

Electrical Power and Fibre
Optic)

Umbilical Subsea Subsea Control

Christmas Tree
Termination Distribution Module

In-field Umbilical Electrical and Electrical

(Hydraulic, hydraulic jumpers Downhole
Electrical Power jumpers hydraulic hard
and Fibre Optic) 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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Production Control System

Key takeaways:
Safe operation

Availability

Simple and robust

Electro-hydraulic

All electric

Increased amount of information

Obsolescence

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