Industrial Automation

and Optimisation

Advanced
HPU Control
Solutions
HYDRAULIC POWER UNITS (HPUs)
HPUs are a popular choice for safely actuating
large safety valves to cut off the flow of oil and
other process fluids in case of emergencies.
They supply hydraulic power to motors, hydraulic
cylinders, valves, and other complementary
parts of a hydraulic system by pressurizing
hydraulic fluid centrally, and then routing the
fluid via specialized hydraulic piping to the
equipment requiring power.
Multi-stage pressurization networks are used to
attain the high actuation pressures required. At
times normal operating pressures can exceed
400 Bar. Temperature also has to be controlled
in order to assure consistent HPU performance.
The mechanical characteristics and specifications
of HPUs are determined by the particular
application and service for which they are being
designed.
Connecting HPUs to plants is generally well
defined mechanically in terms of the gauge
of couplings to be used, and the operating
pressures, flows and temperatures required.
However, challenges become apparent when
considering the control systems of the HPU.
Modern HPUs are typically controlled by PLC-
based analog and digital control algorithms for
safe startup, operation, and shutdown.
There are many brands of PLC available, with
multiple models within each brand. This means
that it is challenging to ensure the appropriate
HPU data is available to other dependent
systems across the plant control networks
There are also many approaches to developing
the HPU control strategies, and we often find
that these are not in line with the control schema
adopted by the rest of the plant.
The consequences of these HPU control system
practices are:
• Last-minute customization of the HPU control
strategies close to the time of commissioning
the full plant
• Incompatibility of communication networks,
necessitating on-the-fly adaptations and
compromises
Matrikon Moore | 2
• Additional training of maintenance staff
• Dependence of specialists to support the
HPU control system
An ideal HPU control system should:
• Use control-system hardware that is
common to, and compatible with the rest
of the plant control architecture
• Follow the control strategies laid down for
the plant
• Provide all the data necessary for safe plant
operation
• Provide a common look and feel to operators
In today’s flexible control environment it is
possible to provide the ideal HPU control
system by recognizing the challenges outlined
above early on in the project life-cycle.
In the long term a fully integrated HPU control
system makes for safer and more economic
plant operation.
OUR HPU SOLUTIONS
WE FREE-ISSUE THE CONTROL HARDWARE
TO HPU OEM
This approach requires agreement between the
client, the HPU vendor and the subsea master
control station (MCS) vendor to standardize on a
common control-system platform.
Once the platform has been agreed we will then
determine the control hardware best suited for
the HPU control strategy, and free issue this
equipment to the vendor.
We also provide the necessary detailed design
documentation so that the vendor can fabricate
cubicles and install the equipment. This typically
includes:
• Architecture diagram and zone ratings
• General arrangements drawings
• Heat and power calculations
• Typical loop drawings
• Etc.
Results
99 Seamless integration into the MCS, rather
than interfacing, which could lead to
performance issues
Testing is streamlined when the MCS and HPU
99 Hardware design based on best practices and control system are developed under one roof.
fit for purpose
Since the control systems are on a common
99 Design based on SIL or zone requirements
platform there is no need for integration testing.
99 Hardware design flexible to incorporate
Results
safety and non-safety I/O
99 The end client has a unified control system
99 Flexible design allows for local and remote
that facilitates streamlined startup, and is
operation of the HPU
easier and more cost effective to operate
WE PROGRAM THE HPU CONTROL SYSTEM 99 Common look and feel for operators makes
In this solution the HPU vendor provides us with for safer plant operation
the HPU control strategy, which specifies exactly 99 Software designed for optimal performance
how the HPU should be controlled. and response from a safety perspective
We then translate the control strategy into 99 Designed for independent operation in the
software code for the control system. event of comms failures
Given that we configure the MCS, we are well 99 Local and remote control of field devices
positioned to ensure that the HPU control and safety overrides
strategy is in line with the control philosophies 99 Remote, manual and automatic control via
implemented in the rest of the plant. control schemes
Shutdown and interlock strategies are aligned 99 Flexible sequencing to accommodate a
with the rest of the plant, thus giving assurance range of control strategy changes
of consistent implementation, and hence safer
operation.
Matrikon Moore | 3
ANATOMY OF OUR HPU CONTROL STRATEGY

Subsea Control System

Common communications buses and control architecture

Typical main control page

Conceptual Architecture

Control Modules and I/O

Hydraulic Power Unit (HPU)

High-pressure services

Low-pressure services
Typical pump-control
faceplate
Control signals

Matrikon Moore | 4 Matrikon Moore | 5

HPU CONTROL-SYSTEM SUCCESSES
HPU CONTROL SYSTEM
N’Goma FPSO (Offshore Angola)
Scope: PLC equipment and software for control of HPU
Project locations:
• System configuration: Johannesburg, South Africa
• Final commissioning: Offshore Angola
Project duration: 22 months (intermittent)
FPSO N’Goma had need of an HPU to supply high-pressure hydraulic fluid to operate valves
located on subsea Wells and Manifolds.
Different types of valves require either a high-pressure (HP) supply or a low-pressure (LP)
supply, so both are supplied to subsea via redundant feeds within an “umbilical” structure
(the umbilical carries hydraulic fluid, chemicals and power lines to the subsea installations).
On N’Goma, there are three such umbilicals, constituting a total of six HP lines and six LP lines
from the HPU.
The HPU unit is located within a hazardous zone classification region, and as such all
equipment had to be appropriately rated for this environment.
The HPU PLC is responsible for controlling the pumps and for monitoring and maintaining
tank levels, supply pressures and flow rates to subsea. Various safety features and shutdown
algorithms are programmed within the PLC, including operation and lockout features on
safety vent valves. The PLC is integrated into the FPSO subsea DCS system, with operator
viewing and interaction possible from the remote CCR, but the PLC is also fully independent
of the DCS system and capable of running in stand-alone mode.
Advantages
99 Fully integrated into the Subsea DCS system, allowing for seamless engineering, operation
and plant visualization.
99 Fully standalone capable to allow for ongoing operation in the event of loss of
communications to the CCR.
99 Shutdown and interlocking philosophy consistent with that of the subsea DCS.
99 Ease of maintenance of individual modules by virtue of segregation into separate
enclosures.
Matrikon Moore | 6
HPU CONTROL SYSTEM
Kizomba B FPSO (Offshore Angola)
Scope: Software library for control of the subsea HPU
Project locations:
• System configuration: Johannesburg, South Africa
• Final commissioning: Offshore Angola
Project duration: 19 months (intermittent)
Extensions to the subsea development for Kizomba A and B FPSOs required new wells and
manifolds to be installed on the seabed in order to tap into newly discovered oil reservoirs
beneath the sea floor. Flows from the wells and manifolds are regulated through control
valves that are operated by high-pressure hydraulic fluid supplied by a Hydraulic Power Unit
(HPU) located on Kizomba B.
An HPU Control system situated on the HPU mounting platform is responsible for control and
monitoring of the high-pressure pumps, supply tanks and delivery pipelines to the subsea
system. In addition to standalone control of the HPU the control system is also responsible
for critical safety functions such as dumping the hydraulics in the event of major platform
shutdowns.
Moore was responsible for supplying the PLC software library and HMI graphics for the HPU
control system and provided final integration of the HPU into the MCS system – the HPU
supplier was responsible for application of the software library and PLC code generation to
meet the specific control requirements for the HPU.
Advantages
99 Fully integrated into the Subsea DCS system to present the Operators with a common
look and feel.
99 HPU supplier was able to retain responsibility for the PLC code, whilst the standardized
software library ensured seamless engineering, operation and plant visualization.
99 Fully standalone capable to allow for ongoing operation in the event of loss of
communications to the CCR.
99 Shutdown and interlocking philosophy in accordance with the HPU supplier’s
requirements.
Matrikon Moore | 7
 Key Clients: Contact us:
info@moore.co.za

South Africa Head Office (Johannesburg)

Tel: +27 (11) 466 1673

South Africa (Vanderbijlpark)

Tel: +27 (16) 932 4471

South Africa (Secunda)

Tel: +27 (17) 631 2744

USA (Houston)
Tel: +1 832 631 6349

Europe (London)
Tel: +44 777 265 1605

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61511 certified.

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