An Introduction to Subsea Control

CONTENTS

The History Of Subsea Production Control. ..................................................... 2

Sub-sea Well Heads ...................................................................................... 11
Opening a valve at the bottom of the Sea ...................................................... 11
Simple system ............................................................................................ 11
Sub Sea valve operation control .................................................................... 12
Direct control .............................................................................................. 12
Sequenced Control..................................................................................... 13
Electro-Hydraulic Control systems. ............................................................ 15
Multiplexed Control Systems. ..................................................................... 16
Multiplexed Electro-Hydraulic. .................................................................... 16
Subsea Control Modules (SCM) .................................................................... 17
Control Modules. ........................................................................................ 17
The Function of the Subsea Control Module .............................................. 17
Subsea Electronics Module. (SEM). ........................................................... 19
Directional control valve (DCV). ................................................................. 19
Valve Manifold Block. ................................................................................. 19
Internal Pressure Transmitters. .................................................................. 22
Shuttle valves ............................................................................................. 22
Accumulators.............................................................................................. 23
Safety Precautions.................................................................................. 24
Filter Units. (Last chance) .......................................................................... 24
Electrical Connectors. ................................................................................ 24
Power Inductive Couplers. ......................................................................... 24
Power conductive Couplers ........................................................................ 25
Hydraulic connectors. ................................................................................. 25
SCM Mounting Base (ROV installed system) ............................................. 25
SCM Mounting Base (Diver installed system) ............................................ 25
The Pod lock system. ................................................................................. 26
Pressure Compensation ............................................................................. 27
Fig2 ................................................................................................. 28
Reduced Umbilical Systems .......................................................................... 29
Comms-On-Power...................................................................................... 29
Subsea High Pressure Intensifier ............................................................... 29
Subsea Chemical Metering ........................................................................ 29
Fill / circulation pump as fitted to Hudson and Foinaven ................. 39
Lower well construction and components ...................................................... 53
 Introduction To Sub Sea Control

The History Of Subsea Production Control.

Modern day offshore oil exploration and production has become a highly
technical operation. Pinpoint accuracy along with hard fact have taken over
from the “wild cat” days of lets try here. Modern technologies now run the
business, much of which was learnt and developed in the 1960's space race
There is very little difference going into outer space or travelling into the inner
space of the world's ocean depths. In the early 1960’s the offshore oil
industry was a small concern, with only fields in shallow waters being
developed, as offshore production had many problems. The risk of pollution,
the maintaining of control, moving the product ashore, weather and cost. In
the late 1960's as man was preparing to walk on the moon the first major gas
strikes were made in the shallow waters of the Southern North Sea. This was
met with great excitement with industry leaders announcing on television that
by the end of the 1970's all the homes and factories in the UK would be fed
with this new free product and gas bills would be a thing of the past. The
British public was bombarded with slogans 'high speed gas', 'cookability that's
the beauty of gas', 'North Sea gas' and the little blue flame man was seen on
bill boards across the nation. By the late 1970's gas bills were as high as ever
and oil and petrol prices got higher and higher as the doom and gloom
merchants forecast that the world's oil reserves would be used up by the turn
of the century.
As the first of the North Sea gas was thundering up from the depths and
making its way slowly to the homes and industry of the UK, 200 miles east of
Aberdeen new records were being set in deep water drilling (deep water in
1968 was 500 ft.). The hope was originally to strike gas in the Northern North
Sea so that Scotland could share in the gas without the need for long pipe
lines. But what they found in the North was very different from the gas in the
south - it was black and runny and there seemed to be no end of it. So
started the boom time of the North Sea. Armies of American businessmen
invaded Aberdeen as the North Sea Oil industry exploded into life. Every field
find seemed to be bigger than the last. Working in water depths of around
600 ft soon proved to be no challenge but did mean that the limit of
exploration was the continental shelf.
Up in the far North, right on the edge of the shelf a new field was struck.
Magnus was a complicated field but had great potential. Being on the edge of
the shelf it had been cut up with faults and had become clear that to
effectively produce would be difficult. To improve this it was required to drill
an additional seven wells around the drill centre below the platform. These
satellite wells would be used for production initially but later changed to water
injection as the field got older. In the shallow waters of the southern sector
their satellite wells would have been produced to small unmanned platforms
but in the deeper waters of the north the option would not have proven to be
cost effective.
Oil Bearing Sands
Traditional Development
Traditional Field Expansion
E xpansion using S ubsea W ell
Expansion using M ultiple
Subsea W ells
W h y B o th e r w ith a P la tfo rm ?
A S u b se a D e ve lo p m e n t

9
Sub-sea Well Heads
A new technology had been used with some success in other areas. This
was to place the well head control tree on the sea bed instead of on the
platform. The valves on the tree would be controlled hydraulically from the
control centre on the platform, either by direct hydraulics or sequenced
hydraulics. These systems have proved to be very good so long as the off-set
is not too long. The case for Magnus was that the offset was long with the
added complication of having seven wells. Each well had to be able to read
back its production pressure. Magnus selected a new form of control called
multiplexed with sequenced hydraulics as a back-up. The control modules
were produced by N.L. Scheffer that had a good track record with blow out
prevention control systems. The multiplex electronics was produced by
Marconi Avionics Offshore Projects Group in Nailsea, Bristol. The system
was designed with several back-up modes with dual redundancy on electronic
subsea systems. Each well was individually powered and controlled. The
system was installed and commissioned in 1981/82 and is still in use today.
In 1988 in the same area of the North Sea the first complete field was
developed using subsea control. The Don field was situated 11 kilometres
from the Thistle Platform from which the four well field would be controlled
and produced. The Don control system was supplied by GEC Avionics
Offshore Projects Group with the control modules being built on their behalf
by Brisco Engineering. Although a small field Don proved that the way ahead
for offshore production was the subsea control field. These early control
systems were designed to be installed by divers but as time went on and
more and more systems were being installed the industry realised that the
way to the deep water oil 500 metres + would be using sub-sea systems.
With more and more concern regarding safe diving and saturation divers
being limited in their dive depth the ROV (Remote Operated Vehicle)
intervention systems were developed, with the control system, well head and
the export pipe work all being able to be installed and maintained by ROV.
The oil companies are now taking their first steps over the edge of the
continental shelf into the North Atlantic. This is opening up all new challenges
that must be addressed and conquered if we are to continue in our great
quest for black gold.

Opening a valve at the bottom of the Sea

Simple system
You just place a man at the valve, with a telephone. The control room can call
him up and ask him to open or close the valve at any time. Oh! And while he
is at it maybe he could read the pressure and temperature in the pipeline at
the same time.

Could it be this simple ?

11
 Sub Sea valve operation control
Assuming a standard pressure to open and a Spring closed Actuation. There
are basically 4 types of control available. ( not including the one above).

Direct control
From a hydraulic power source on the surface, run a hydraulic hose down to
each valve. Pressurise and it opens, vent and it closes.

For
It's very simple and reliable.

Against
One hose for each function.
There would be a long delay in pressurisation and de pressurisation owing to
the hose length.
There would be no indication that the valve had moved.

Direct control can be and is used where there are a small number of valves
close to the pressure source.
Example:- Sub Sea Isolation Valves. (SSIV's)

12
Sequenced Control
Sequenced control can be used where a series of valves need to be set in a
known set of combinations.

Example:-
Valve Position’s
1 2 3 4 5
A Closed Open Open Open Open
Set Up

B Closed Closed Open Open Open

C Closed Closed Closed Open Open
D Closed Closed Closed Closed Open
E Closed Closed Closed Closed Open

This type of control can be achieved with only 2 hoses. One to supply the
actuation pressure and one to supply a pilot pressure.
To organise this requires a piece of equipment to be installed close to the
valves that are to be controlled. This unit is commonly known as a subsea
Control Module (SCM). The subsea control module would be fitted with a
number of pilot operated directional control valves (DCV's). The number of
these valves corresponding to the number of valves that are to be controlled,
except in more complicated situations.
Using different piston sizes on the pilot stage of each DCV, will result in the

DCV's piloting across to there open positions at different pilot pressures.

Example
Assuming a full pilot pressure of 250 Bar.

Valve 1 could be set to pilot at 50 Bar

Valve 2 could be set to pilot at 100 Bar
Valve 3 could be set to pilot at 150 Bar
Valve 4 could be set to pilot at 200 Bar
Valve 5 could be set to pilot at 250 Bar

13
These pressures being regulated at the hydraulic power unit control panel.

For

Only 2 hydraulic lines are required.

Against

Only pre determined valve sequences allowed.

No indication as to valve position.
Over long offsets can be slow in operation.
Valve positioning may be erratic.

14
Electro-Hydraulic Control systems.

This system once more uses a subsea control module (SCM), but this time
fitted with electrically energised directional control valves with no hydraulic
pilot stage. They are energised electrically from the platform individually. As
each valve would require its own signal 5 wires (for a 5 function system) and a
common would have to be run to the SCM from the platform. But only one
hydraulic hose.

For

Only one hydraulic hose.

Total control of each valve.
Fast in operation.

Against

No valve position indication unless further wires are run.

Multiple subsea cables.

15
Multiplexed Control Systems.

The ideal system would be one that can open and close any number of valves
almost instantly and can confirm that the valve has been energised. But can
also read back other information such as product flow rates, pressures and
temperatures. All using one hydraulic hose and 2 electrical cores, without
siting a man on the sea bed with a telephone.

Multiplexed Electro-Hydraulic.
The number of conductors needed in the communication circuits can,
however, be minimised by using a multiplexed (mux) system. Rather than
having a specific electrical circuit for each control function, a single circuit is
used, with additional intelligence to allow a particular signal to be routed to a
particular solenoid pilot valve. This system is capable of controlling a large
number of actuators very quickly, and using a relatively small umbilical.
In principle, the umbilical need only contain a single electrical power line and
a signal line, and a hydraulic supply line (though in practice additional
functions would be added). It is even possible to combine the electrical power
and signal onto the same pair of wires.
Furthermore, multiplexed systems also permit the retrieval of data multiplexed
onto the same communication circuit as for control. Such data plays a crucial
role in helping the reservoir engineer to monitor the status of production, and
thence to maximise reservoir recovery and/or productivity. Additional sensors
can be incorporated to optimise production, without impacting on umbilical
complexity and cost.
Operationally the multiplexed system requires smaller umbilicals and less

deck space than all other systems, and provides a monitoring capability not
otherwise available economically. The speed of operation is greatly superior
to that of all-hydraulic systems. As a result, the E-H mux system is now used
on all but the least demanding subsea production systems.

16
 Subsea Control Modules (SCM)

Control Modules.

Individual tree and manifold control is provided via subsea control modules
(SCMs) . These modules contain the valving and multiplexing software
required for routing of hydraulic fluid to the various valve and choke actuators.
Additionally, all monitoring of subsea systems status is accomplished in this
module.

Each module includes at least one subsea electronics module (SEM), pilot
valves and some transducers. A universal module (i.e. all modules having
identical configuration) is recommended to allow module interchangeability
and to reduce system cost.

In abnormal operation, when electrical communication is lost, all pilot valves

fail as they are. The system can then be kept in production by use of the
hydraulic supply lines. Conversely, all production valve actuators are fail-safe
when hydraulic pressure is removed. Thus, the system can be shut-in by
removing the control supply pressure to shut all tree and manifold valves, and
secured by removing the high pressure supply to close the downhole safety
valves.

Design of the interfaces to the subsea control module is entirely dependent

upon whether the module is diver-assisted or diverless retrievable. Diverless
systems are inevitably more complex, requiring self-alignment features of all
the hydraulic and electrical connectors.

The Function of the Subsea Control Module

The SCM purpose is to :-
Supply and control pressure supplies to hydraulically actuated valves.
Provide conformation of actuator movements.
Read back system pressures and temperatures
Read back production pressures and temperatures.
Read back information regarding its own well being.(House keeping values)

The above list is for ever getting longer as more and more technology is
forced into its operating parameters. Such advancements include.
Down hole flow metering.
Chemical metering.
Boosting the low pressure hydraulic supply to provide the high pressure
supply.

17
Sand production metering.
Production flow metering.
Corrosion sensing.
Multiple well control.

As a result of the diversity of the SCM's operating parameters. Each project

will have different requirements and so each project requires a different SCM
design.

Diver installed SCM (electrical face shown)

(Ninian platform protection)

Diverless control module

Pompano shown
Major components of a subsea control module.

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Subsea Electronics Module. (SEM).
The subsea electronics module (SEM) is used to transmit and receive the
digital information between the Master Control Station (MCS) and the subsea
system.
Down link commands from the MCS are interrogated by the SEM’s processor
that trigger commands to the SEM components, such as the 24 volt solenoid
drivers that command the open or close solenoid on each DCV to function.
It also receives the analogue 4-20 mA signals from the various transmitters
and converts them to a digital signal that are passed to the up link to the
MCS.
The SEM’s are powered from the control umbilical, with around 100 volt
although this can vary from project to project. The uplink and the down links
are carried on two wire cores within the control umbilical. On a PC based
MCS the 2 wires will carry all the uplink and downlink communications for up
to 32 SCM’s. New technology now allows the communications (uplink and
downlink) to be carried within the power umbilical cores. (Power on comms).
For the MCS to talk to a particular SEM, it needs to address the SEM. Each
SEM is given an address number. For the MCS to communicate with a SEM,
the SEM must be logged onto the MCS by use of its address number.

Directional control valve (DCV).

Pilot valves are used to route hydraulic fluid to an actuator, in response to an
electric or hydraulic signal. In E-H systems, a solenoid is used to move a
poppet within the machined body of the pilot valve. The solenoid is driven by
special I/O circuits within the electronics module.

Pilot valves should be as simple as possible and a two-position three-way

valve is preferable. It is important to note that one solenoid pilot is used to
effect closure, and another used to effect opening. This means that under
normal conditions, neither solenoid is energised, and this minimises the
power consumption of the control system. Each solenoid can also carry two
coils for redundancy. It is also important to note that the main piston is spring
loaded. This ensures that the valve moves to its closed position if hydraulic
supply pressure is lost.

The life of the valve will depend on the hydraulic fluid that is selected; the
cleaner the fluid, the longer the life. NAS 1638, class 6 is being specified for
most systems in the North Sea. It is essential that these components are
assembled with the greatest possible care. Reliable control valves already
exist, but the aim of the manufacturers must be to make them more tolerant of
dirty operating fluids.

Valve Manifold Block.

All the pilot valves in a module are assembled together on a manifold block.
This minimises the hard piping needed. A complete. set of pilot valves will
usually include one valve to perform an 'arm' function. This is a function which
must be activated after a shut-down, before any other function will operate.

19
The reason for this is to ensure an orderly start-up sequence after any
interruption in the hydraulic supply.
The valve type generally used on all Vetco Gray Controls systems comprise
of a pilot operated 2-position 3-way valve, with the pilot section activated by 2
solenoid valves. One valve is used for opening the main valve and the other
to close it.
The solenoids are powered by 24 volts supplied by the SEM and only require
a momentary pulse to engage the pilot pressure, one to three seconds being
all that is required, thus reducing the power required to and from the SEM.
The solenoid duration time is set by the SEM and can be changed easily from
the MCS.
The valve closes by spring pressure. This moves the valve to the closed / vent
position once the pilot pressure has been vented or the pilot pressure has
dropped to a level where it can no longer resist the spring. The venting of the
pilot pressure is done by energising the closed solenoid.
The valves ability to drop out or delatch when the pilot pressure drops to a
predetermined level is an important feature of this design of valve. By careful
selection of spring the valves can be set to drop out at almost any pressure.
This is used in the systems Emergency Shut Down (ESD). Ideally in the event
of an emergency shut down the valves would be shut down via the MCS in a
set manor that allows the system to be restarted easily. But in the event that
the MCS no-longer has any power or has been knocked out by the
emergency, the subsea production of hydrocarbons can still be stopped by
venting the hydraulic supplies at the HPU (see section on the Hydraulic power
unit). The venting of the pressure would cause the valves to drop out and
close as soon as it has dropped to a level where it can no longer hold the
DCV in its open position. In all production systems, one valve is specified as
the Flow Cut Valve (FCV). This will always be the first valve to close and to
achieve this the DCV controlling that valve will be fitted with a stronger spring
to the others. As the pressure falls from the normal working pressure of 207
bar at 80 bar the DCV controlling the FCV will drop out and the FCV will close
so stopping production. As the pressure continues to fall to 50 to 60 bar all the
other valves will then shut in. (The reason for shutting a well in this way will be
explained in the section on well start up). This type of ESD is normally
referred to as a catastrophic shut down.
Once a shut down has been carried out in this way, depressurising the system
will not reopen the DCV's. the MCS will have to be reset and each open
solenoid valve will have to be energised.
Vetco Gray Controls have for a long time generally used one type of valve
manufactured by Tactair (USA) formally known as Teledyne, but more
recently VG have moved away from the single source and have been using
other valves of different size and manufacture.
In an attempt to maintain more control of quality and design, Vetco Gray
Controls have now developed a DCV to there own design and build. This
valve has already been approved for use on several high profile projects.
Even so they all work in the same way. With the exemption of one or two
where the customer requested that the DCV controlling the FCV must be a
permanently energised open valve. This type of valve is held in the open
position by the solenoid. As soon as the power is removed the valve will move
to the closed position. As a result if the power is removed from the MCS for

20
any reason including maintenance the subsea production would stop, this has
never been popular with platform operators.

21
Internal Pressure Transmitters.

The number and location of pressure transmitters within an SCM, is generally

dictated by the client. There is almost always one on each consolidated
supply (down stream of the shuttle valve) and sometimes one on each supply
(up stream of the shuttle valve) and the best systems have one on each
function out put.

The pressure read by the transducer is converted into a reading between 4

and 20 milli amps. 4 mA reading zero pressure and 20 mA representing the
full scale of the transmitter. This information is sent to the SEM that intern
sends it to the MCS. The MCS converts it back into an engineering unit (psi or
bar).

If the SCM has been fitted with transmitters on the function out puts, when the
DCV goes to the open position the transmitter will see pressure. The initial
pressure will be low as the hydraulic fluid pressure is being used to move the
actuator; it may drop to only 150 bar. This information is sent to the MCS
which is programmed under this situation to assume that the valve is moving
and tells the operator. Once the out put has recovered to its normal working
pressure the MCS will assume that the valve is now open and will tell the
operator. (The MCS is programmed with an expected time for the valve to
operate in. If the pressure continues to show low after this time has expired, it
will send out an alarm.)

There is one internal pressure transmitter also fitted inside the SEM itself. As
the SEM is a pressure vessel and the internal pressure is at one bar, if the
pressure was to increase it would indicate a leak. So the pressure within the
SEM is constantly monitored by the MCS.

Shuttle valves

The HPU and the umbilical deliver to the subsea system two services of low
pressure hydraulic power and two services of high pressure hydraulic power.
This is to allow for full duel redundancy of the hydraulic supplies. In the event
of the loss of one of the supplies, the other supply must be able to continue to
maintain the system pressure without loss by returning to the depressurised
supply. This is achieved at the SCM with shuttle valves (see fig).

22
It is only once inside the SCM that the 2 supplies are merged or selected by
using the shuttle valve. Which ever supply is providing the highest pressure
will be selected. The pressure from the higher pressure supply closing of the
lower pressure supply. In the example the A supply will be shut of as the
pressure from the B supply is forcing the ball against the a seal. If the
pressure on the A supply is equal to the B supply, the ball will float allowing
pressure to be taken from both sides, but as soon as the pressure on one side
drops lower than the other it will be sealed.
The shuttle valve will allow an entire subsea supply to be vented, without any
loss of pressure on the back up channel. This is a feature that has proved to
be essential in many system integration procedures.
Note:- The SCM's supplied to Amerada Hess for the Hudson field, although
fitted with shuttle valves, where also fitted with an electronic equivalent using
solenoid operated DCV's and pressure transmitters. These where requested
by AHL owing to the bad reputation for failing to seal that shuttle valves had at
one time.

Accumulators.

At one time it was normal to group all the SCM's together on a subsea
template or on the manifold and with them would be a pair of accumulator
modules, one for each hydraulic channel. As the majority of our SCM's are

now fitted on the well head trees themselves, they have to provide there own
stored hydraulic energy.

23
Accumulators are fitted for two reasons. One is to damp out any hydraulic
shocks and the other is to provide a store of pressurised fluid that can be
called upon at times of great demand. Such as opening a large actuator,
where the supply down the umbilical cannot keep up with the actuators thirst.
Vetco Gray Controls uses 2 types of accumulator within our SCM's. The most
common type are the nitrogen charged bladder type (see Fig **). These are
general-purpose accumulators suitable for use with a variety of pressures and
pre-charges. But if the pressure is to exceed 7500 psi (gauge) then the
nitrogen charged piston accumulator is selected. (See Fig **)
Safety Precautions.

Gas charged accumulators must only be charged with dry nitrogen. Oxygen
for example, will cause a massive explosion if it comes in contact with
hydraulic oil or grease owing to the dieseling effect.

Any work on hydraulic systems incorporating accumulators must only be

carried out after release of the pressurised fluid.

Gas bladder accumulators should normally be mounted vertically with the gas
filling valve at the top.

Accumulators should be securely fastened to prevent them being torn from

their supports by recoil in the event of fracture in the piping system.

For maintenance work on accumulators, adhere strictly to the instructions

provided by the manufacturer.

Filter Units. (Last chance)

The requirements of a clean system will be mentioned in the HPU section.
Even though the hydraulic fluid supplied from the HPU is to the cleanliness
standard required. The consequences of damage caused by dirt to the
subsea system, has resulted in the fitting of very fine 3 micron last chance
filters on each of the inputs into the SCM and also an additional filter on the
pilot pressure supply.
These filters have no blockage indicators but are fitted with a by-pass valve in
case of such an unlikely event

Electrical Connectors.

Making up power electric's subsea has always provided a problem as

electrical voltage and sea water do not mix.

Power Inductive Couplers.

In the mid seventies, an idea was tried to connect power cables by inducing a
current in one transformer winding with an other, but with a visible gap

24
between the two windings. If each winding was encased in a plastic shell it
was possible for the two halves to be mechanically pushed together under
water and current could pass between them. To achieve the best results 400
Hz power was used. This system of connecting power and communications
subsea was used up to the Troll and Hudson projects in the mid Ninties.

Power conductive Couplers

These projects used a conductive coupler. The Troll project using a Lockheed
connector and Hudson using a Tronic connector.
Diver Mateable instrument connectors (Hydrobonds)
Power conductive couplers are very precise pieces of equipment, with a very
high integrity. As a result they are also very expensive. Since the Brit-oil - BP
Don project in 1988 all diver installed SCM'S have used Hydrobond
connectors for all there instrument connections. The Hydrobond is a simple
rubber connector (usually 4 pin) that when screwed together expels enough
water to maintain a seal good enough for low voltages (24 volts for 4-20 mA
sensors typical)

Hydraulic connectors.

For a long time VG failed to standardise on a specific type and manufacture of

couplers. This was mainly owing to the wide variety of connectors and
customer preferences. it was not until the ROV installed SCM's became the
normal that VG standardised on the National connector for base connections.
These units have a good track record and rarely require any attention.

SCM Mounting Base (ROV installed system)

This is a carbon steel structure permanently integrated onto the Xmas tree,
Manifold or Template. Its Top Plate houses hydraulic couplers and electrical
connectors. These connect hydraulic control functions to the tree and
manifold valve actuators and electrical monitoring from various tree sensors,
via mating couplers and connectors in the SCM base plate.

SCM Mounting Base (Diver installed system)

In the case of a diver installed system, there is no requirement for base plate
connections. The diver will make up the hydraulic and electrical connections
by hand, normally on the side of the SCM. The SCM mounting base in this
case will normally consist of a method of securing the module to its location,
so as to prevent movement.

25
The Pod lock system.

As field water depths have got deeper and deeper, it has became necessary
to dispense with all types of diver intervention.
Placing the hydraulic and the electrical connectors on the bottom of the SCM
has allowed the SCM to connect to the subsea functions just by landing the
unit on to a suitably equipped landing base that has been mounted on to the
subsea structure. Once the unit has been landed so that the couplers have
made up, it is then necessary to hold the SCM in place, as high function
pressures would easily lift the module off. It is also necessary to line up the
two halves accurately and to bring them together in a slow controlled way
(soft landing). Contrary to popular believe this is not done by the running tool
(see section on running tools page 62), but by the pod lock (also known as
retlock).

The podlock is installed in the centre of the SCM’s base plate with its
actuation drive protruding through the top of the top cover and its latching Nub
protruding through the bottom of the base plate.
As the SCM is lowered on to its landing base the 2 alignment pins orientates
the couplers. The Nub of the Podlock engages in a cut out in the centre of the
base plate and the nub takes the full weight of the SCM. In this position none
of the couplings have made up or even made contact.
The large drive nut at the top of the SCM is now turned clockwise. This is
done by the ROV via the running tool if the SCM is subsea. Or by hand if it is
on the surface. The first ¼ turn engages the nub. A further 22-23 turns will
then be applied. This action will draw the nub towards the base plate. In so
doing pulling the SCM slowly onto the Landing base, making up the
connectors.
Turning the drive anti-clockwise drives the nub back out and so jacking the
couplers slowly apart. Once more the last ¼ turn disengages the nub from the
landing base allowing the SCM to be recovered.
After the SCM has been installed for a number years there was concern
voiced by many that the podlock mechanism may seize causing the recovery

26
of the SCM to become in some cases impractical. To satisfy this potential
situation a second drive is fitted to the top of the assembly. When the correct
tool is used with this drive it causes a sheer pin to fail, allowing the nub to
travel the ¼ turn to unlatch the SCM without jacking the unit up first.

Pressure Compensation

When possible it is always preferred to design subsea components to be free

flooding, allowing the internal void areas to fill with sea water. Items such as
umbilical termination assembles and accumulator modules are almost always
designed this way.

The subsea electronics module (SEM) obviously can not allow ingress of
water, or the pressure that the water is under, as this pressure can effect the
calibration of certain items within its circuits.

Fig 1

Owing to these factors, the SEM must be enclosed in a pressure vessel that is
designed to withstand the seabed pressure where it is to be located. As part
of its Factory Acceptance test (FAT) the SEM will be tested to 1.5X the
working pressure. In the case of Foinaven some well heads are at 57 Bar
water pressure, so the SEM will be tested to 85.5 Bar.
Vetco Gray Controls have a policy of installing monitoring devices within the
SEM vessel that can read back to the MCS the internal pressure and
temperature of the SEM. This information can be used as an aid to fault
diagnostics as well as give prior warning of a leak in the SEM vessel.

27
 Fig2

Other components within a Subsea Control Module (SCM) will not generally
be affected by the sea pressure. They would not be seriously affected by sea
water in the short term, but it would reduce the unit’s life owing to external
corrosion on hydraulic components and eventual ingress of sea water into the
electrical connections. To avoid this the SCM housing is made waterproof and
filled with Transformer Oil (Dielectric oil). This oil is an insulating oil that can
absorb small quantities of water to maintain the insulation.

Fig 3
Filling the SCM with oil at atmospheric pressure (1 Bar) will present problems
when the SCM is run subsea. Unless the SCM housing is a pressure vessel
the SCM housing would crush under the differential pressure between the
subsea pressure and the 1 Bar oil pressure inside the SCM. This can be
avoided by fitting a flexible barrier between the oil and the sea. This can take
the form of a rubber bladder fitted to the top of the SCM junction box with sea
water on the outside and oil on the inside (ref fig1). Or it may be by having the
bladder fitted inside the junction box with oil on the outside and sea water on
the inside (ref fig2). Or it could be achieved by making the whole side of the
junction box a sheet of rubber (ref fig 3). The barrier would allow the pressure
of the sea to be transferred to the oil, but for it to work fully would require
almost total air exclusion from the oil. If this is not achieved the barrier may
run out of flexibility before the compensation is achieved, as oil will not
compress but a Gas will.

This is achieved during the oil filling process. During the oil filling the SCM is
connected to a vacuum pump that is used to pull the pressure in the SCM
junction box down to 30 mbar or less. The vacuum will be held for a period of
time and the pressure monitored to ensure there are no leaks that would be
indicated by an increase in pressure. The oil will then be pulled in with the
vacuum. By doing this the level of air entrapment will be kept to a minimum.
During this process the compensation bladder will be filled with a known
volume of water and sealed to prevent the bladder from expanding owing to
the vacuum.

28
Reduced Umbilical Systems

The umbilical represents a large investment in CAPEX (capital expenditure)

and installation cost and it is therefore of interest to the operator to reduce its
complexity in order to keep these costs to a minimum. Vetco Gray Controls
has various control system hardware options available which help in
optimising the system including the umbilical. Examples of some of these
options follow:

Comms-On-Power

To reduce the number of electrical cores in the umbilical the process of

overlaying the communications signal onto the subsea power supply can be
employed. This effectively halves the number of electrical cores required in
the umbilical and reduces the number of subsea electrical interfaces. Vetco
Gray Controls has developed the use of Comms-on-Power modems. These
are installed in the MCS and SCM in place of the standard modems used in a
conventional system.

Subsea High Pressure Intensifier

The SCSSV is usually the only high pressure function required to be

controlled by the production control system. In order to control this single
function a dedicated high pressure hydraulic line(s) is required in the
umbilical. In order to reduce umbilical size, Vetco Gray Controls has
developed the subsea High Pressure Intensifier to eliminate the requirement
for this high pressure line(s). Installed in the control pod it takes its supply
from the low pressure supply, as used by the valve actuators, and boosts it to
the high pressure required to control the SCSSV. Additional cost savings
associated with the use of the High Pressure Intensifier include the reduction
in hydraulic couplings throughout the system and a reduced functionality HPU
(only needs to generate low pressure hydraulic supply).

Subsea Chemical Metering

Depending upon reservoir conditions some field operators may need to have
chemicals injected into the subsea well at a metered rate. The conventional
means of achieving this is to have individual chemical lines for each tree in
the umbilical, with the rate at which the chemical is injected controlled topside.
This means for every tree that requires chemical injection an additional line or
lines are added to the umbilical, on a large field development this can add up.
Vetco Gray Controls has developed the use of Chemical Metering Valves
sited in the subsea control module to allow the metering of chemicals subsea

29
from a common header supplied by a single line in the umbilical. This means
that a large subsea field development, e.g. for 12 trees, the number of
chemical lines required can be reduced from 12 to potentially one (depending
upon flow rates required). This can potentially give a massive saving in the
umbilical and associated installation costs especially where long offset
distances are involved.

30
 The Master Control Station
It is not intended to go into fine detail on the subject of the MCS within
this course as other courses dedicated to the subject are available.

The Master Control Station (MCS) shown at Figure 4 provides the primary
means through which the Platform control system (PCS) can control and
monitor the subsea production control system. A local MCS Engineering
station provides independent system control when necessary.

Fig 4 The Hudson MCS with the EPU to the Right.

(Vax Based)
The MCS provides a means of operating all hydraulically actuated subsea
valves, via the SCM. It will automatically monitor subsea sensors, via the
appropriate SEM, transfer this information onto the DCS via the serial link as
well as displaying the received data on the Engineering station if requested.
The MCS interfaces with the HPU and EPU sensors and transfers this
information to the DCS as well as displaying the received data on the
Engineering Station if requested.
The MCS consists of one or two 19 inch computer rack which contains the
following equipment

VAX System FIO

(PLEASE NOTE VAX SYSTEMS ARE NO LONGER SUPPLIED)
• Subsea Controllers (Computers A & B)
• On Line Selector (OLS)
• Visual Display Unit (VDU)
• Keyboard and associated drawer
• Graphics generator Unit
• Alarm/Indicator Status Panel
• Circuit Breakers
• FSK Isolation Boards
• Termination Rails.
• DCS/ PCS Modems

31
PC System
• Subsea controllers (computers A&B although some systems only have
one)
• On line selector (OLS) but not if only one computer is fitted.
• Visual display unit (VDU)
• Computer selector (black box)
• Key board & mouse.
• Subsea Modem units (SMU's)
• Circuit breakers
• Termination rails.
• HPU motor control relays.
• DCS / HPU / PCS modems.

The operation of the MCS is controlled by the two Subsea Controllers. Both
controllers are identical and interchangeable containing the same operating
system. One computer is designated the "Active" machine it takes control, the
other machine designated as "Standby" collects and processes the same
information but controls no outputs.
The active machine will routinely update the standby machine, as necessary,
via an interprocessor link. Should a failure occur in the active machine the
standby machine is then ready to take immediate control of the system.

The following modules are used within the computers

• A Main Processor Board with memory expansion and built in Ethernet
Controller
• A Winchester Disc, a TK5O 95 Mbytes Tape Streamer and controller
board. Or PD and CD drive..
• Input Conditioning Boards which handle the Discrete Input/Outputs and
the serial interface.
• FSK Modems which handle the subsea communications. Or subsea
modem units (SMU's)
• A Watchdog board which monitors the operation of the computers.

The Winchester / hard drives discs hold all the program and data files, whilst
the data streamers or optical drives are incorporated for program
dissemination and back up purposes.

The input conditioning falls into three areas

• Discrete inputs which provides monitoring of the OLS, EPU and the
ESDs.
• Discrete outputs which provide remote annunciation of faults and HPU
recirculation pump and motor control.
• Serial Interfaces, to the HPU and the PCS.

32
VAX Based Systems.

The FSK links consist of the FSK modem boards within the controllers and the
FSK isolation boards which are within the MCS cabinet. The former provides
the drive for the subsea communications link whilst the latter provides D.C.
isolation between the subsea link and the computer system
The FSK links are read only by the active controller and only the active
controller will handle the outputs. To ensure that both controllers have up to
date information an interprocessor link is provided.

PC Based Systems

With the introduction of the PC based computer, the use of FSK modem links
where dropped in favour of the TC57 system that is now incorporated in all
VG new build systems. With the use of conductive subsea connectors the
need for 400 Hz power sub sea is no longer required. The old style Electrical
power units (EPU's) have now been mostly replaced by Subsea Modem units
(SMU's). These 19" rack mounted units supply the power and
communications to the subsea system, as well as providing Line insulation
monitoring.

The On Line Selector (OLS), which is used to switch serial and digital outputs
to the active controller dictates that only one of the controllers will be active at
any one time. The OLS monitors the watchdog output from the controller and
should the active controller fail it will enable the other controller to take
control.

The Local Engineering Station consisting of a keyboard, and a visual display

unit although this will normally be powered down. It can however be used to
provide an operator terminal if the PCS fails, it can also be used for off line
servicing. Although to log onto the local engineering station as an operator
removes the control from the PCS.

Different levels of operator access to the system is obtained via the keyboard
using passwords, this ensures that only authorised personnel can perform the
relevant tasks.

33
 Electrical Power Unit (EPU)

The EPU provides the 60Hz a.c or 400Hz power for the SCMs and the 24
volts D.C. power used by the surface equipment, the EPU is usually powered
by the existing UPS.
The duplex subsea power supply uses two 1KVA multi-tapped transformers
with an output range of 240 -335 volts. Each transformer has a padlockable
isolator and a circuit breaker in the primary circuit. Each transformer has a
voltmeter, an ammeter and an output status relay in the secondary circuit.
Each subsea power supply has a line insulation monitor (LIM) which is able to
measure the insulation resistance of the umbilical cable. The Lim will de-
energise a contractor in the transformer primary circuit if the adjustable
present level is exceeded owing to earth leakage.

The LIM provides a status output and also has an ohmmeter to display the
line insulation resistance, it is also capable of operating while the umbilical is
unpowered.

The 24 volt power supply which powers the HPU interface modules and the
MCS consists of two 24 volt supplies each capable of running the entire
system. The supplies have their outputs consolidated.
Each 24 volt supply is protected by a circuit breaker in its input circuit. The
output circuit provides current limit and over voltage protection The power
supplies provide a status output as well as an output indication.

The EPU often used to house the barriers and interface modules associated
with the HPU. The data is relayed to the MCS normally by two RS 232 serial
links.

34
 Subsea Electrical Philosophy
The subsea electrical system consists of power and communication links. It
utilises conductive or inductive couplers which have both diver and Remotely
Operated vehicle (ROV) style connectors.
The Subsea Electronics Modules (SEMs) are installed within the Sub Sea
Control Modules (SCM) provide the route through which the subsea wells are
controlled and monitored
The SEMs have the ability to activate the solenoids associated with each of
the Directional Control Valves (DCVs); activation is by command of the
surface Master Control Station (MCS) on a check and operate basis. Tree,
manifold and SCM transducer information is also passed to the MCS.
Communication with the MCS is via a dual high integrity communications link,
ensuring correct solenoid operation and avoiding monitored data corruption.
The MCS will continually monitor the traffic across the in use channel and in
the event of a communications failure automatically switch to the other
channel maintaining system control. In the event of a total failure the
communications system will be left in its 'On Failure" condition.
Power to the SEMs, which is also duplex is supplied by the surface Electrical
Power Unit via dual cables within the umbilical. The dual power supply is
consolidated within the SEMs and is continually monitored and its status fed
back to the surface. The system can operate on a single supply but in the
event of a complete failure the system will be left in its 'On Failure" condition.

35
 Hydraulic Power Unit
HPU

The Huson HPU

This is a large unit mounted on the topside of the system.

The Topside is the term used to describe the area that is not Sub Sea ( on the
Sea
Bed). This can be a fixed platform, a floating platform or dry land.
The HPUs purpose is to generate the hydraulic pressure required to activate
the
various valves within the subsea System. To control a normal subsea well
head the
HPU is required to produce 2 pressures. A low pressure (LP) that is normally
207 bar
or 3000 psi and a high pressure (HP) this can be ether 345 bar 5000 psi or
517 bar
7500 psi.
The low pressure (LP) is used for general hydraulic power, for valve actuation.
The High pressure (HP) is only used to operate the Down Hole Safety Valve.

The hydraulic medium used on subsea control systems is a water glycol

mixture,
although in the past mineral oil has been used its use is now considered to be
not
environmentally friendly (as leak's are hard to detect) or economic as a return
line
from the subsea system is required (Closed System).Water glycol on the
other hand is environmentally friendly and can be and vented directly into the
sea using a total loss system requiring no return line. (Open System)
Owing to the use of a total loss hydraulic system there is no actual return to
the HPU

36
of used Hydraulic fluid. Even so Vetco Gray Controls do advise that the HPU
is equipped with
2 reservoirs, a supply reservoir and a return reservoir. To understand this a
knowledge
of hydraulic cleanliness is required.

Hydraulic cleanliness and the NAS class system.

Dynamic hydraulic components, have by nature to consist of fine tolerance
sliding
fits. The fine tolerance, has to be geometric, linear and surface to achieve the
seals
required to contain the high pressures used. If the surface finish of a dynamic
sealing
face is scratched, the scratch could become a leak path across the seal. If not
it could
become a harbour for particles that would then abrade a leak path. For this
reason all
efforts are made during manufacture to maintain a high level of finish and
cleanliness.
Having gone to this effort at manufacture it is also necessary to maintain the
cleanliness during use and for the systems designed life.
To achieve this the fluid that is used has to be cleaned and filtered to a
standard of
particle contamination that the system is known to withstand, without undue
ware.
The first organisation to become aware of this requirement was the
Aerospace
industry. There use of small light weight Hi-integrity components that needed
definitive service intervals called for a set of cleanliness levels that could be
related to
the life of each component. To this end the National Aeronautical standard
1638 was
introduced. (NAS). The standard has 14 classes of particle contamination, 00,
0, 1
through to 12, the higher the standard the higher the level of contamination
allowed.
The level that is approved by Vetco Gray Controls for use in there products is
referred to as NAS Class 6 (or better).
This means that for every 100 ml sample of fluid taken the maximum number
of
particles in 5 size ranges must not exceed the following.

5 to 15 Microns 16000
15 to 25 Microns 2850
25 to 50 Microns 506
50 to 100 Microns 90
Over 100 Microns 16

Refer. To Vetco Gray Controls document ZZ-001-012/Issue 2 for further

information on this subject. (See Appendix)

37
The HPU's Circulation and filling system
All HPU's have to have a method of filling there reservoirs. This is normally
achieved
by use of an integral self priming pump and filter system.

HPU Circulation system.

Hydraulic fluid is supplied by the manufacturer already clean to NAS 6,

although in
transit to the work site this often deteriates to as high as NAS 10. As a result
of this it
can never be assumed that a clean sealed barrel of fluid is clean.
As mentioned before, the HPU is often fitted with a return reservoir, even
though
there is no return. This reservoir is used during the filling process. The fresh
fluid is
pumped via the fill pump into the return reservoir. This keeps the new fluid
isolated
from the fluid that is currently in use. By setting valves within the HPU a return
reservoir clean up circuit can be set.

38
 Fill / circulation pump as fitted to Hudson and Foinaven

Using the same pump as was used for filling the unit, the fluid is drawn from
the
bottom of the return reservoir passed through a large 3 micron filter and then
back to
the return reservoir. This circulation can be left running until a sample that is
to NAS
6 or better is achieved.
Once a clean sample is produced the now clean fluid can be transferred
across to the
supply reservoir, by use of the same pump.
This system is known as the fill circ system and can be used to the following
functions.

1. Fill the return reservoir.

2. Fill the supply reservoir.
3. Transfer fluid from the return to the supply manually.
4. Transfer fluid from the return to the supply automatically when there is fluid
in the
return tank and the supply tank is going low.
5. Circulate the return reservoir to clean up.
6. Circulate the supply reservoir to clean up.
7. Drain the return reservoir.
8. Drain the supply reservoir.

Pressure Pumps
There are basically 2 types of pressure pump used within Vetco Gray Controls
Hydraulic
power units. These are Electric power or Air power. Which type to use is
determined
by the field requirements and the customer preference.

39
Electric pumps.
There are several types of electric pressure pump available, but they all work
on the same principle with a 3 phase electric motor providing the power.
Electric pumps can be specified to produce any combination of flow and
pressure but are not self controlling. A separate switch has to be located
down stream of the pump out put to cut the motor out when the desired
pressure is reached. This can take the form of a pressure switch that cuts the
control power, or a pressure transducer that sends a reading to a PLC unit
that cuts the power when the desired pressure is reached.

Air Driven Pumps.

These pumps are only capable of producing a fairly low flow rate, but can
produce very high pressures. There operation is quite strait forward (see Fig)

It can be seen that compressed air enters the low pressure cylinder of the
pump. This causes the high pressure cylinder to compress at the other end.
So if the air piston surface area is 10 X the area of the high pressure piston
then the resulting pressure output would be 10 X the pressure of the air
supply.

The pressure out put from these pumps is directly proportional to the air
pressure input. So the pressure control can be easily and accurately
achieved by regulating the air input to produce a pressure balance at the
desired level.

Motor control
It has already been mentioned that the pressure pumps must be controlled so
as to shut them down when the correct pressure has been achieved. It is also
necessary to be able to restart them when the pressure falls, in some units
fitted with 2 pumps ( a duty and a stand by) the system needs to be Monitored
so that if the pressure falls to a pre determined low low level both pumps will
start.

40
It is necessary to make all the pumps stop operating and an alarm warning
given in the event of the supply reservoir being run to a low level, or an
emergency shut down (ESD) of the platform is required.

Different projects have different HPU requirements. The motor control may be
provided by local pressure switching with all power control being internal and
as such represents a self contained unit. Other systems such as the Britannia
HPU, the power from the motor managers is controlled by PLC's within the
subsea engineering station (SES). With this system the PLC's receive a
switching point from the SES that is provided by read-backs from the HPU's
header pressure transmitters. The SES also monitors the other HPU read
backs and will stop or inhibit the pumps in the event of low fluid level. This
provides the operator the ability of changing the start and stop point
pressures, from the SES key board. Where as with the pressure switch type a
technician is required to reset the pressures at the switches within the HPU.
The more common control system is to connect the motor supplies directly to
the motor managers in the platform switch room. The pressure switches on
the HPU are wired to relays in the back of the Master control station (MCS).
These in tern switch on and off the 110 volt start and stop circuits to the motor
managers and at the same time send a signal to the computers stating the run
state of each pump. If air driven pumps are fitted this obviously has no effect
and the MCS assumes that the pump is energised, unless the air supply is
fitted with a pressure transmitter that will inform the MCS if the pressure drops
to a level that can no longer energise the pump.

Pressure Relief valves

Each pressure pump output must be fitted with an over pressure relief valve
that is capable of venting the full flow of the associated pump. This relief valve
must be hard piped into the system and must not be given any form of
isolation from the pump outlet

System Filter Units

Each pressure system (HP and LP) is fitted with a pair of 3 or 5 micron filters.
These are fitted into the system as the first component after the pressure
pumps have been consolidated.( see Fig). The filters are fitted as pairs to
allow each to be isolated for maintenance without effecting the functionality of
the HPU. In some systems the filters are fitted within a manifold with 2
position 3 way valves fitted so that only one valve can be selected at a time. It
is essential that a third valve is fitted so to allow the venting of pressure after
the filter has been isolated. It has proven impossible to remove the filter bowl
to allow changing of the element without this feature.
In the event that during normal service the duty filter becomes blocked a valve
in the head of the filter body opens allowing the fluid to bypass the element.
This will be signalled both locally by a visual indicator and remotely to the
MCS via a desecrate signal from a pressure switch fitted to the filter head.
Accumulators

41
To dampen the system, protecting it from hydraulic shock and to store
pressurised Fluid for "on demand" use, all HPU's are fitted with a number of
hydraulic gas filled Accumulator units. These are fitted in the LP and HP
common header. They are normally of the Bladder type, but on some units the
piston type are used in the HP system. The fluid connection to the
accumulator is always protected with a relief valve and a block and bleed
valve system to assist in maintenance without the need to vent the complete
system.

Typical HPU Accumulator bank.

2 small units are HP

Emergency Shut Down

As all valves controlled in the system are of the spring return type, removing
the hydraulic pressure will cause them to close. The HPU is equipped with
vent valves on each of the outlets. These valves are solenoid operated and
are held in the open position via a 24 volt signal from the platforms fire and
gas emergency shut down (ESD) system. The ESD system has several levels
of operation. Depending on the severity of the situation that has led to an ESD
to be initiated the power to these valves may be isolated, so causing the
valves to shift into there vent position bleeding down the subsea pressure and
causing all the valves to close. This level of shut down would be in the
catastrophic level as the valves would close in a random manor making
restart difficult. For a full understanding of ESD system refer to the section on
ESD sequencing.

HPU Interfacing

42
The HPU is normally interfaced to the PJB by hard tube work, providing 2
High Pressure supplies and 2 Low Pressure supplies, as well as a PJB return.
If an air pump is used then an air supply will be connected from the platform
instrument air supply. This will be regulated within the HPU to provide the
pressure balance required to maintain the desired hydraulic pressure. Also in
the air supply will be fitted a solenoid valve that can cut the air supply and
stop the pump in the event of an emergency shut down.

The 440 volt supply to the electric pumps will be supplied from the motor
managers in the platform switch room. The signals from the pressure switches
will go to the Motor control cabinet (MCC) on the HPU. These will become
part of the motor control circuit along with the reservoir low level cut out
switches, manual pump enable switches and the local emergency stop
buttons. If all these switches are closed then a 24 volt signal will be sent to the
MCS that will close the contacts on the motor manager and the pump will start
to run.

Other information about the HPU is provided to the MCS via a serial link.
These are the analogue values and include. Reservoir levels, header
pressures, individual out put pressures (down stream of the ESD valves) and
filter condition.

The final interface is the 24 volt supplies to the emergency shut down valves
(ESD). This supply comes from the platform fire and gas panel. Depending on
the nature of the shut down can close and vent any of the hydraulic outputs
and via the MCS inhibit any pump starts.

Hydraulic Power Unit Location

The HPU when installed on a fixed platform (jacket) will normally be placed on
the lowest deck and open to the elements. Some units have been fitted in
closed modules but this is unusual. When installed on a floating unit such as
an FPSO (floating production storage and off loading vessel), the HPU would
be installed in the mooring turret. It is always attempted to locate the HPU as
close to the platform junction box (PJB)as possible.

43
 Platform Junction Box (PJB)
The Platform Junction Box, or PJB, is the interface between the topside
system and the subsea umbilical.

It is normally installed at the point where the control umbilical rises onto the
platform. This is normally the lower most deck or even on a cat walk below the
lowest deck. The PJB is connected via hard tubing directly to the out puts
from the HPU. It will also if required be hard piped back to the subsea
chemical injection unit.

To provide a connection for the power and comms going subsea a junction
box is fitted. This is connected to the power from the Electrical Power Unit
(EPU) and the Communications from the Master Control Station (MCS).
The PJB will normally be furnished with a series' of block and bleed valves
and a gauge on each pressure out put (hydraulic or chemical). These are to
provide the following functions.

• Block and isolate the umbilical.

• Flush the pipe work from the pressure sources, while the umbilical is
blocked (so as to retain pressure subsea.
• Simulate leakage's within the umbilical, to check the subsea response.
(shuttle valve testing).
• Testing emergency shut downs (ESD) without venting subsea
pressure.
• Testing emergency shut downs (ESD) without venting top side
pressure.

The platform junction boxes used on directly controlled sub sea isolation
valves (SSIV). Are often used as a control unit. The PJB may be fitted with
electrically powered ESD valves on each subsea outlet as well as pressure
transmitters Electrical and Hydraulic sub sea distribution system.

44
 Subsea Control Umbilical
The umbilical is used to connect the topside control and chemical systems to
the subsea system. With the offsets between the topside and the subsea
getting longer and longer and longer the umbilical is often the most expensive
single component of the system.

Built by specialist manufacturers the umbilical is made is one length with no

joints. The longest used with the VG system was 45 kilometres long. An
umbilical to control a production subsea control system would normally
consist of three 5000 psi hoses for the LP hydraulic, three 10,000 psi hoses
for the HP hydraulic. Any number of 8000 psi chemical hoses. These vary
from contract to contract and are dependent on the field requirements. Six 2
core power and communications cables.

The components are laid together with fillers and packers between each part
to provide a firm and stable pack. The bundle is then wrapped in a nylon
wrap before being coated in a hard rubber sleeve. This is then bound with an
armoured left-hand spiral wrap of stainless steel wire 1/8" diameter. This is
then coated in bitumen before a second armour right hand spiral wrap of
stainless wire 1/8" diameter. Once again this is coated in bitumen, finally
wrapped with hemp coloured to the customer requirements. The manufacture
is continuous with no joints in any of the components. The hoses and cables
are manufactured and layered at a one off process.

Each end of the umbilical length requires a method of termination. The

umbilical termination assembly (UTA) is the subsea end of the umbilical. This
is generally a boxed structure that the umbilical is attached to. Inside the box
the umbilical internals are allowed to emerge from the armouring of the
umbilical structure to allow termination to the electrical and hydraulic
connectors located around the outside of the UTA. The topside end of the
umbilical is sealed off to stop water ingress during installation. It is fitted with
a collar from which the umbilical will eventually be hung and the end if fitted
with a pull head referred to as a bull nose.

Load Out

During manufacture the subsea/UTA end is made first and as the umbilical is
made it is spooled onto a horizontal powered drum up to 10 metres in
diameter - this is known as a carousel. Once complete the umbilical will be
tested on this unit prior to load out. The lay vessel will also be fitted with a
carousel. During load out the umbilical will be transferred from one to the
other so that the subsea end is the last part to be loaded onto the vessel. If
the umbilical is to be used with a diver installed system the UTA will be small
enough to allow it to be fitted to the umbilical prior to load out. If it is to be
used with a ROV installed system the UTA may have to be fitted after the load
out owing to its physical size. The load out duration time varies according to
the length of the umbilical but 24 to 36 hours is quite common.

45
Installation

Once on location in the field the UTA with the umbilical attached will be
lowered down to the seabed. The UTA will be pulled in and be secured to its
landing point. This may be at the manifold, a distribution structure or
sometimes the ETA may be free standing on the seabed (Foinaven). With the
ETA secure the lay vessel will move off towards the platform, laying the
umbilical as it goes into a pre-ploughed trench. A survey vessel will follow
monitoring the progress by an ROV, before a plough vessel covers it in again.
Once at the platform the bull nose at the end of the umbilical will be attached
to a pull line which is fed from a winch on the platform, down a pipe know as
the 'J' tube to the sea bed. The remaining umbilical will be lowered to the sea
bed and then using the winch will be pulled up the 'J' tube. The umbilical will
eventually be hung from the top of the 'J' tube. Once this has been done it will
be possible for the umbilical to be terminated into the platform junction box.
Once installation is complete and all testing has been carried out successfully
the bottom of the 'J' tube will be sealed around the umbilical. The cavity
between the 'J' tube and the umbilical will then be flushed of sea water and
replaced with clean potable water.

Reduced Umbilical Systems

See SCM Section on these developments.

The umbilical represents a large investment in CAPEX and installation cost

and it is therefore of interest to the operator to reduce its complexity in order
to keep these costs to a minimum. Vetco Gray Controls has various control
system hardware options available which help in optimising the system
including the umbilical

46
 Weak Links
Many customers in the past, chose to lay large sections or even the entire
umbilical on the sea bed unprotected by trenching or rock dumping. These
umbilicals were at risk of being snagged by trawlers or ship anchors, if located
in shallow waters. Such snagging could rise to the umbilical being dragged
across the sea bed causing damage that could only be rectified by the total
replacement of the unit, at huge cost.
To resolve this problem one end of the Subsea jumper or umbilical would be
protected by a weak link. The weak link may take on several forms but the
most common was where the jumpers that ran from the UTA to the subsea
structure passed through holes cut into 2 sliding shear plates. One plate
would be connected to the structure and the other connected to the UTA. The
UTA would be connected to the structure by a shear pin. In the event of an
incident the shear pin would brake, the UTA would be pulled away from the
structure causing the shear plates to slide against each other as they came
away physically slicing the hoses and cables. This is a fail safe option as the
cut hoses would vent all down stream pressure causing all the valves to close.
A repair would require the manufacture and fitting of a new set of jumpers but
in theory the umbilical would not be damaged.

The main umbilical UTA weak link assembly under test installation on the
Hudson manifold. Note the sheer gates in the open installation position and
the swivelling reaction post on the right.

47
The same Hudson weak link after the gates have been closed. (note only 2
hoses installed for test.

Photos taken at the Nigg Bay fabrication site, during the 1994 Hudson
manifold integration test.

Another popular type used on the smaller subsea jumpers that run from the
manifold to the trees, consist of two plates fitted with hydraulic and electrical
connectors. The two plates are held together with a shear pin latch. In the
event of an incident the shear pin would brake allowing the two halves to
separate.

The valve side of the hydraulic connectors are not fitted with self sealing
valves so the valves would close but the controlled side would be fitted with
sealing valves so stopping fluid pressure blowing away. If the valve side was
fitted with sealing valves it would not be possible to vent the pressure leaving
the valves and the well / wells uncontrolled.

Weak link fitted to a Hudson tree

48
 Subsea Electrical Distribution
The UTA at the sub sea end of the umbilical provides 1 pair of channel A
power and communications and 1 pair of channel B power and
communications. As the power and communications have to be shared by all
the SCMs a method of splitting has to be provided. This is done by connecting
the UTA power and communications to an electrical distribution module
(EDM).

The Lyell Electrical distribution module

Fitted with inductive couplers.

The cannel A and B power and communications come in on one side with the
correct number of outputs to power all the SCM's in the system, with
additional outlets for future expansion, as well as through connections to
connect a second system.

49
 Subsea Hydraulic Distribution

One of the 2 Hudson Hydraulic and electrical power/communications

Distribution modules.

As with the electrical distribution, the Hydraulics and chemicals have also to
be distributed. This is normally carried out with a closed loop header system
with block and bleed valves fitted at each outlet. This allows an SCM to be
removed without venting down the entire system and in doing so shutting
down production on the entire system.

50
 Well Construction

Contrary to popular opinion, an oil well is not a hole drilled in the ground with
a cavern full of oil at the bottom. The oil is held in a bed of sand that acts like
a giant sponge. A well is an intricate and complex peace of engineering and
is increasing in complexity all the time. In any field development the most
expensive component to produce and commission is the well its self.

Drilling a well on a new field is a dive into the unknown. Even with all the
high tech survey equipment at the geologist’s disposal there is still no
guarantee that what they find will be oil, gas, water or an interesting strata of
sand stone with a huge fault down the middle.
Modern drilling techniques have helped. With the advancements in directional
and horizontal drilling techniques the geologists are able to tune the wells
arrival into the field by studying the rock cuttings pushed out of the well by the
Mud. From this information the driller can kick the drill off in a different
direction, or even pull back a few hundred feet before trying another angle.
It has become common practice in modern wells to enter the field horizontally.
This allows the perforation of the well to be carried out over a long length.
This practice improves production as the oil is drawn from a larger area of
sand with less velocity across each orifice so reducing sand production.
A well is initially drilled as a series of steps getting smaller and smaller. As
each step is drilled it is lined with a steel tube and the gap between the tube
and the rock filled with cement. This provides a very strong foundation for the
start of the well. The main section is drilled at between 12 and 7 inch
diameter and may be steered and controlled in any direction, but still is
sleeved and back filled with cement.

51
The drill pipe or string is made up of sections of pipe. Mud is pumped down
the centre. The angle that the mud is jetted into the cutting bit controls the
direction of the drill. The mud then returns up the outside of the drill string
taking with it all the drill cuttings. As the mud arrives back on the rig its return
is regulated causing the well to remain at pressure. The mud travels through
a peace of equipment known as a shale shaker that removes all the cuttings
before being pumped at high pressure back down the well through the drill
string.
Finally arriving within the field, the oil is held down by the pressure of the mud
that is pumped down the centre of the drill string and the backpressure
maintained on the return. Sampling the returned mud and analising its
content gives the reservoir engineers the information that they need about the
well and field. From this information they can calculate when and where to
finish the drilling process.
With the drilling complete the well is closed of at the bottom with steel and
concrete allowing the mud pressure to be removed and the well cleaned.

52
Lower well construction and components

With the well complete, the production tubing is run down. The tubing divides
the annulus from the production. The production pressure can vary over a
time, the tubing is allowed to flex with the linear expansion. If there was no
tubing and the product allowed to flow up the annulus the temperature
changes would cause the Steel and concrete to crack. At the start of the
tubing is fitted a device called a perforation gun. This device is used to brake
away the concrete at the base of the well to allow the oil or gas to enter. It is
an explosive device, which makes the operation of perforating a well very
hazardous. Above the perforation gun will be found the Down Hole Pressure
and Temperature gauge. (DHPT) above this is the Down Hole Safety Valve
(DHSV). Above this is the long run up to the Tubing hanger on the seabed
from which it is all hung.

53
 Actuators
Spring close Gate valves.

There are several types of actuator that the VG control system will be required
to function. The most wide spread and simplest is a basic spring return gate
valve. These valves are fitted in the well head trees and in various locations
on the distribution manifold. Hydraulic pressure from the SCM is used to act
on a piston that pushes against a spring and pulls the gate to and open
position. When the pressure is vented the spring pushes back, so closing the
valve. These valves come in various sizes from small 1" units for Chemical
injection, to large 10" units for production flow cut valves on the Tree and

manifold.
Spring closed Ball valves

These valves are used primarily as sub sea isolation valves (SSIV's). There
operation is basically the same as the spring operated gate valve but has the
benefit of a ball valves speed in operation, positive sealing, does not increase
the pressure in the system on closing and when open presents no restriction
to the flow. There main draw backs are they are very expensive to
manufacture and only seal in one direction. Actuated ball valves can range in
size from 6" to any size that a spring can move, the largest controlled by a VG
system is on the Ninian Solm Voe SSIV and the Cleeton Dimligton SSIV at
36"each.

Hydraulic actuated open and close Ball Valves.

54
These valves are also used for SSIV systems, but do require stored hydraulic
accumulated power subsea to effect a close. The largest of this type of valve
controlled by a VG system is the Solom voe SSIV valve bellow the Ninian
Central platform, at 36"dia.This style of valve is also used as a pigging valve,
as full control of this type of valve is necessary and accidental closing can
prove to be expensive.(see section on pigging operations).

Hydraulic actuated open and close Ball Valves.

These valves are also used for SSIV systems, but do require stored hydraulic
accumulated power subsea to effect a close. The largest of this type of valve
controlled by a VG system is the Solom voe SSIV valve bellow the Ninian
Central platform, at 36"dia.This style of valve is also used as a pigging valve,
as full control of this type of valve is necessary and accidental closing can
prove to be expensive.(see section on pigging operations).

Choke Valves

Choke valve (Britannia)

The purpose of the choke valve is not to open or close completely, but to
restrict the flow when required to very precise tolerances.

There are currently 2 types of choke valve readily available. The most
common type is the stepped unit. This choke moves from the open to the
close, or closed to open, position via a series of steps 1 through to 100. So
each step represents 1% of the total travel. The steps are produced by
opening and closing a DCV in the control module. Each open and close
actuates a pawl and ratchet, so moving the choke 1% one way or the other.
This is a very slow process, with some chokes taking over half an hour to
complete a full travel from closed to open.
Within the SCM there are 2 DCV assigned to each choke one to pulse it open
and one to pulse it closed.
The second type of choke is the motor driven type. This is a hydraulic motor.
Once more controlled by 2 DCV's.. Much faster than the step type, but gains
its position information from the 4-20 mA sensor, as a result is not as
accurate.

55
 The actual motion of the choke, is monitored by a 4-20 mA sensor. This
sensor is connected to the SCM that reports the true position of the choke to
the MCS.

Down Hole Safety Valves (DHSV) or (SSSV)

The down hole safety valve, is a simple flap valve that is fitted inside the
production tubing right down toward the bottom of the well. They require high
pressure hydraulics to open them as the actuation pressure has to passed
down to the valve a long way through a very small tube. The resulting
restriction produces a massive reduction in pressure at the valve. Also the flap
valve has to be opened against the well pressure. This would not be possible
unless the differential pressure across the valve is reduced to almost zero.
The valve will close on loss of pilot pressure or if the flow rate across the
valve reaches a pre set limit. This feature is to protect the well in the case of
loss of control at the well head.

56
 The Well Head Tree
The Well Head Tree is the production control unit at the top of the well (the
well head).
It was given the name of Christmas Tree when they first appeared in the
Middle Eastern deserts as from a distance there appearance was that of a
Christmas Tree.
The modern subsea equivalent bears little resemblance although it does the
same job.

A Hudson Field Tree.

(A Vertica ltree, shown on its flow base with a control umbilical weak link
fitted)

The well head stump will have the top of the well production tubing exposed
normally 5" dia. with a smaller 2" tube next to it that connects to the wells
annulus. There will also be 2 electrical and one hydraulic connections. These
are to provide power to the well perforation system, communications to the
down hole pressure and temperature gauge (DHPT) and hydraulic actuation
pressure for the down hole safety valve (DHSV).

57
Down hole pressure and temperature transmitters. (DHPT)

In the last few years these gauges have proven to be very popular, as the
information that they read back is very useful to the reservoir engineers as
well as production.

The gauge is fitted in the production tubing, just bellow the down hole safety
valve. Owing to its location even if all the valves are shut in the pressure and
temperature of the field can still be read. The readings sent back are
commonly 3000 psi and 140 DegC.

The gauges are normally about 30 mm in diameter and 1meter long. They
provide a varying frequency up a single wire and armoured cable (this looks
like co-axe cable). The information is processed by a card within the SEM that
is supplied by the gauge manufacturer, prior to it being passed up to the MCS.

Down Hole Safety Valves (DHSV) or (SSSV)

The down hole safety valve, is a simple flap valve that is fitted inside the
production tubing right down toward the bottom of the well. They require high
pressure hydraulics to open them as the actuation pressure has to passed
down to the valve a long way through a very small tube. The resulting
restriction produces a massive reduction in pressure at the valve. Also the flap
valve has to be opened against the well pressure. This would not be possible
unless the differential pressure across the valve is reduced to almost zero.
The valve will close on loss of pilot pressure or if the flow rate across the
valve reaches a pre set limit. This feature is to protect the well in the case of
loss of control at the well head.

Traditional Vertical Trees

Flow Base

Flow Base

58
On to this stump is fitted the trees flow base. This is a flat square frame with
4 guide posts (one on each corner). It is fitted with an interface to the
production flow line to connect the tree to the manifold, as well as connections
for control power, hydraulics and chemical injection.

The Tree
On to the flow base is fitted the well head tree.
A basic tree will consist of 4 hydraulic operated valves and 2 manual valves
(ROV operation).

Production Master Valve (PMV)

Often known as the lower production master valve (LPMV). This will be a
large hydraulic open spring closed gate valve. With this valve closed all tree
functions will be isolated. It normally has a slow travel time. Opening may
take as long as 100 seconds.
On some trees a second PMV valve may be fitted known as the upper
production master valve (UPMV). This valve can only be opened or closed by
ROV intervention and is for maintenance only.
It is a legal requirement that before any attempt can be made to brake into a
hydrocarbon system for any reason, there must be a minimum of 2 blocks
between the product and the intervention. If the production pressure
transmitter is to be replaced on a live well both the LPMV and the UPMV must
be closed. Above the PMV is the trees production core. It is within this area
that the production temperature and pressure will be measured and read back
to the SCM and any chemicals will be injected into the well flow.

Production Wing Valve (PWV)

The PWV is the trees out put valve. It can also be used with the PMV to
create a double block to the well if work needs to be done on the flow base on
the flow line. The PWV is often designated as the flow cut valve (FCV) by the
ESD system. The flow cut valve is the valve that is used to scam the oil flow
off in an emergency. This places a great deal of stress on the valve. The
AWV is used as it is down stream of PPT so with the AWV closed the tree

59
head pressure is still known and is locked into the system. (A well pressure is
required for well re-start. See Section on Well Commissioning).
Production SWAB Valve (PSV)

The PSV is located at the very top of the tree block. It is only activated by
diver/ROV as it will only be opened during work over operations when the tree
cap is removed and an LRP is installed. It's primary role is that of a double
block to the tree cap.

Annulus Swab Valve (ASV)

The ASV is located at the very top of the tree block. It is only activated by
diver/ROV as it will only be opened during work over operations when the tree
cap is removed and an LRP is installed. It's primary role is that of a double
block to the tree cap.

Annulus Master Valve (AMV)

The well annulus is a void space around the production tubing. It's basic role
is to provide cushion for movement of the production tubing caused by
temperature and pressure changes. Recently it has been also used to pump
gas down the well for gas lift operations.
Oil rising from the field is hot but as it rises will cool down. This has to be
monitored by the PPT and APT and the pressure balanced by operation of the
cross-over valve. If this is neglected it has been known for the production
tubing to collapse or split.

The Tree Cap

The tree cap closes at the top of the tree and acts as a second barrier to the
SWAB valves.

60
When fitted it also hydraulically connects the actuators to the SCM via tube
loops.

When the tree cap is not fitted the SCM will have no control over the tree
valves. This is to allow the work over control system to take over when the
lower riser package (LRP) replaces the tree cap.

Prior to starting tree control testing through an SCM always check with the
tree vendor that the tree cap is fitted as SCM testing is the only time it is
required and it often cannot be seen from the ground.

Horizontal Trees

In resent times many companies have opted for the new Horizontal Tree
design. The advantages of these trees is there low profile. Some operators
include that the tubing hanger is part of the tree as being an advantage, as
the tree must be run before the production tubing is run. Once the tubing has
been run the well can be immediately tested and used. Other operators
consider this to be a disadvantage, as to recover the tree the Tubing must
also be pulled.
Horizontal Tree

61
 Tree installation
Emergency disconnect package (EDP) and Lower Riser Package (LRP)

Foinaven Tree fitted with its LRP and EDP.

62
63
 Well Start Up

With the well perforated and complete for production. All tree valves must be
in the closed position, this includes the production choke. The first valve to
open is the DHSV. The opening of this valve will cause hot crude oil to rush
up the well to the PMV. This action would cause the oil to cool very quickly,
causing an effect known as slugging. Slugging is where the oil cools quickly
causing it to wax and take on the consistency of tar. Another effect is that the
production tubing would heat up the annulus and expand the methanol in the
annulus void, upon opening the PMV and PWV the oil would flow causing a
drop in pressure in the production tubing. This can cause the increased
pressure in the annulus to crush the production tubing. This is known as tube
collapse and is considered to be the most expensive failure in oil exploration.

Depending on the tree design this can be avoided by opening the AMV and
the XOV. In doing this the pressure across the tree is balanced. Methanol is
then injected into the well from the trees Methanol injection point above the
PMV. with the PMV, The XOV, and the AMV all open the methanol is injected
into the well. The pressure transmitter at the AMV or Above the PMV monitors
the pressure. Allowing for the depth of the DHSV and the DHPT the system is
pressurised to a pressure equal to the field pressure.

To open the DHSV there should be little differential pressure across the valve
(The DHSV is a flap valve that opens against the flow).

With the production tubing, annulus and tree core pressurised to field
pressure and confirmed by the production pressure transmitter A command
may now be sent to the DHSV to open. As the well bore is full and to
pressure, the DHSV will now open but owing to the lack of differential
pressure there will be no rush, but instead the crude will mix with the
methanol and slowly warm the well. No slugging or waxing should occur.

As the AMV and the XOV are open the annulus and the production tubing will
now be at an equal pressure. It is important that this state exists during start
up as the warming up of the production tubing will cause the tubing to expand
into the annulus causing the annulus pressure to increase. If the annulus is
fully filled with liquid the production tubing will be unable to expand, defeating
the purpose of the annulus and causing the tubing to be damaged.

With the well and tree bores stabilised, the production wing valve may now be
opened. With the PWV open all that is stopping export is the chock valve. The
chock valve must be opened slowly to no more that 50% at this time.
Otherwise waxing and slugging will occur in the export system (be that the
manifold, template or flow lines).

The first oil from a new well or field will always be initially flared off. It is
surprising how long it takes for the product to flow to the topside facility on a

64
new development. The AHL Hudson field with an 11 Kilometre offset took 9
hours to push through to the Tern alpha.

Chemical Injection Point Frequency Frequency

Methanol Production Trees Prior to and during
start up. Whenever
a long shutdown is
anticipated
Corrosion Inhibitor Production Xmas Continuous once The production
Trees watercut develops tubing will not be
protected by this
system
Demulsifler Production / test Continuous if
Headers on Manifold emulsion problems
occur
Wax Inhibited Production/Test At low flowrates, Recommended a
Headers and the when arrival dosage of 150
Manifold temperature is low. ppm. Design work
Prior to a planed should assume
shut down. 500 ppm.
Scale Inhibitor Production tree Continuous once The injection point
watercut develops. at the tree will
prevent scale
deposition
downstream of the
choke

List chemicals injected, where and why.

65
 Manifolds

The Britannia manifold.

Probably the last of the giants.

No oil or gas field worth developing would ever be expected to produce

through one well. Owing to the oil bearing strata formation and the need for
water injection the minimum is usually three wells. One water injection and
two production. Once the oil has been produced to the well head on the sea
bed it needs to be flowed to the location of the first process equipment for
separation and pumping. This would normally be an existing platform. As the
subsea wells may be 50 kilometres away from the platform each well would
not have its own flow line back, instead the oil is
flowed from each well to a manifold where all the wells are consolidated into
one

Typical manifold layout with only 2 trees shown for clarity.

66
flow line back to the platform. Subsea manifold are as diverse as anything
used in the offshore. They can be literally two pipes teed into one or they can
be huge cathedral structures capable of controlling and diverting 30 wells
independently down five flow lines, injecting water, injecting chemicals,
monitoring sand production from each well, monitoring corrosion formation
within its pipework, measuring production flow rate from each well as well as
pressure and temperature. They can be so large and so complete in their
ability to monitor and control that they require two full functioning SCMs to
look after them.
Template Manifolds
Template well heads where first used for pre drilling wells prior to a platform
installation. The system is used to accurately space the wells at the sea bed
so that when the platforms jacket is put in place, the risers will line up and
easily connect.
The template system is now being used with subsea completion, by fitting
multiple trees to a common structure that is often also used as the manifold.
This results in the wells being drilled very close together at the sea bed before
they are kicked out into a field spread. The advantages of such a completion
are that the SCM’s can be grouped together with hard piping connecting them
to the tree actuators. This removes the need for subsea jumpers joining the
manifold to each of the trees.
The disadvantages are that with the wells being so close together at the sea

bed, places only a small amount of sea bed medium between each head.
Depending on the structure of the sea bed this can result in the system being
unusable owing to instability. In addition to this, the wells being so close
together, restricts the number of work over vessels that can work at any one
time to one.

67
 Flow Lines
Production Flow lines
Production Flow Lines are the pipelines which flow the raw crude from the
manifold to the first process location (platform or FPSO). Most subsea fields
would have two production flow lines sizes at 8" or 10" diameter.
Manufactured from welded steel they would be laid into a trench which is cut
into the sea bed and buried to avoid damage from passing trawlers etc. It is
normal that one flow line would be defined as high pressure and the other as
low pressure. Crude is delivered from the tree to the manifold. The first
action would to control is flow rate using a choke valve. This valve may either
be fitted on the tree or on the manifold. Once the flow rate is controlled the
pressure and temperature would be measured using a 4-20 mA transmitter.
This is also the point at which a sand detector may be fitted. The product may
now be diverted down one of three flow lines. These are P1HP, P2LP and
test. The reason for the LP and HP flow lines is that well pressures can vary.
One well may be producing at 100 bar but another may be only producing at
30 bar. If both wells attempted to be exported in the same flow line the
production would be very disappointing as a large quantity of the high
pressure well's production would be overcoming the low pressure well and
going back down into the field. The flow pressure well would not produce at
all.

The Test Flow Line

With maybe eight production wells to be consolidated at the manifold into two
production flow lines production from the wells is mixed together. With
exception of temperature and pressure it is not possible to analysis the
performance of one well or to sample the crude from just one well. To
achieve this the one well can be exported down the test flow line. The test
flow line is a small version of the two production flow lines. It is designed to
export from the manifold the production and full flow from one well. This gives
the operators the opportunity to flow test and sample the product from just the
one well.

Bundled Pipelines

68
 Production Enhancement

Water Injection

When a new field is discovered and developed the initial field pressure is quite
high, allowing oil to rise and to force the field pressure alone. As the oil is
removed the pressure drops and production is slowed down. To maintain the
feed pressure new wells are drilled to the field at specific locations. These
wells are identical to production well in construction but are used to inject
huge quantities of high pressure clean water into the field and in so doing
replacing the pressure that has been lost owning to the production.

Gas Lift

Gas lift is a fairly new and has proven very successful as a means of
increasing field production. Recovered gas that would normally be flared off
is re-compressed and pumped down the well annulus where it is re-injected
into the oil production flow. This aeration causes the density and viscosity of
the oil to form, so increasing the rate at which the oil travels up the well.

Gas Disposal Wells

In the past, oil production platforms would only produce oil. Any gas that was
produced being flared of in a thunderous flame that was always associated
with off shore platforms. The image of the flair brought about public concern
and was looked on as being an incredible waist of natural resources. This was
of course was true, but it was environmental pressure that finally all but
stopped the practice. All flaring in the British and Norwegian sectors of the
North Sea is now metered and the operators have to pay a heavy tax on all
gas that has been flared off. “Money talks” and in no time the gas that was
being flared was being exported back to the land.
In the North Sea production facilities are still flaring if it is still uneconomic to
export. But almost all oil platforms will carry a small flair to maintain the
facilities emergency blow down facility and to burn off any over pressure
vented product. This is a system where if an emergency shut down is initiated
all pressurised hydrocarbons are vented to the flair and burnt off.
In the West of Shetland fields, the gas produced cannot be exported as there
is insufficient to be commercially viable. It can not be flared either as West of
Shetland developments are not allowed to flair as a day to day operation.
The produced gas in this situation is reinjected back into the field down a well
called a gas disposal well. It has been found that this action can result in
improved production from adjacent production wells owing to the aeration and
lowering of the density of the oil.

Sand and Corrosion Sensors

When producing oil it is a fact of life that oil is not all that is produced. If it
were then the need for offshore production platforms would vanish. The oil is
held in sand strata that acts like a sponge. When the oil is produced is comes
up with water, gas, hydrate and a quantity of sand that the oil was held in.

69
The water and the gas can be produced back to the platform before it is
separated out but the sand cannot as the erosion damage it can cause to the
system can be catastrophic. Although a level of sand production cannot be
avoided on some field it must be kept to a minimum. This can be done by
careful control of the production rate by the well choke or the gas lift rate via
the annulus choke. To achieve this the actual sand production rate from each
well must be monitored. This has proven to be a challenge. The current
design consists of placing four metal pads in the flow line from the tree.
These read back at 4-20 reading to the SCM. A brand new pad would read 4
mA. The presence of sand would start to erode the pad and in doing so the
current would increase. This would cause an alarm so the necessary action
may be taken to reduce the sand production. After a period of time the pads
would wear out and the reading would be 20 mA. At this time the sensor unit
would have to be replaced, but as long as the operator responds to the alarm
and the sand production has been kept to a minimum there is no reason why
the sensor should not last the life of the system.

Corrosion Sensing
Crude oil contains all types of aggressive chemicals that the cause the build
up of scale within the system or the corrosion of the system. Both effects can
be combated by injection of scale inhibitor or corrosion inhibitor chemicals, but
it is a fine balancing act. Injecting scale inhibitor will stop the build up of scale
but will promote the effect of corrosion. Corrosion inhibitor will help to prevent
the corrosion but promotes the build up of scale. To assist the operators in
knowing what to pump and when many systems are now being fitted with
corrosion sensors at the manifold end of the flow lines. These sensors work
in the same way as a sand detector but instead of the single increasing
owning to an erosion of the pads it is increased by corrosion.
Temperature and Pressure transmitters.
Pressure and temperature transmitters are installed at strategic positions on
the subsea production train.
Commonly. At the tree. 1 between the PMV and the PWV. 1 between the
AMV and the AWV.

Pressure transmitter Fitted to the Hudson Manifold

70
1 Down Stream of the choke valve. 2 (duel redundant)on the start of each flow
line.
These transmitters use the 4-20 mA signal and can be of any range. A
pressure transmitter that has a range of 0-300 bar would read 4mA at 0 bar
and 20 mA at 300 bar.
Flow metering

A standard industrial flow meter consists of a turbine wheel placed in the

product flow. Each turbine blade is fitted with a small magnet, as the product
flows through the turbine it turns, a sensor outside the unit counts the
frequency that the magnets pass.

From this information the flow rate can be calculated. This type of meter is
very good when used with non aggressive mediums such as water and where
easy access for maintenance is possible. They are not suitable for use with
crude oil at the bottom of the sea.

Modern solid state venturi flow meters fitted to the water injection system of
the Hudson manifold

71
In resent years a new type of solid state flow meter has been developed for
this purposes. It works on the venture principle, where a fluid passing along a
pipe is restricted. The pressure across the restriction drops as the flow rate
goes up. If a pressure transmitter is located at the restriction and on one side
of the restriction the 2 pressures can be measured as a differential pressure
and used to calculate the flow rate.

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 Intervention

From time to time all equipment will require maintenance and attention that
cannot be carried out subsea. At this time the piece of equipment will have to
be recovered to the surface for refurbishment or repair.

Diver Installed Systems

The advantage of diver systems is that at this time a diver can do and see far
more that an ROV. This can mean that if a transmitter on a tree fails, a diver
can replace it in situe. While an ROV system would require the entire tree to
be recovered to the surface.

With many diver systems, the SCM's are mounted on the manifold or in
separate structures. This gives the divers ample room to work in and allows
for easy equipment change out, using simple air bags and tirfors.

When being installed by diver, smaller components such as SCM's can be

lowered to the seabed, adjacent to its landing place by the vessels crane.
From this position the component can then be carefully moved into its final
location by air bag.

Larger equipment or equipment that must be installed directly on to its

location, is often run down on guide wires. Guide wires can only be used if the
original equipment was designed for there use.

Guide Wires
A well head tree will always be deployed by guide wire. The 4 wires are run
from beneath the rotary floor (rig floor above the moon pool) through the
moon pool and down to the flow base where they will be attached to the tops
of the 4 guide posts, by ROV or diver. When the tree is moved over the moon
pool the guide wires will be fitted into slots in the 4 guide tubes on each corner
of the tree. Once the wires are all in place they are held in with gates at the
top and the bottom of each slot. As the tree is being run the guide wires are
tensioned causing the guide tubes to follow the wires over each of the flow
base guide posts. This allows the tree to land in the correct orientation without
any other assistance.

Deep Water ROV installed SCM

Balder landing base fitted on the tree

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An SCM that is intended for ROV installation has to be run directly onto its
landing base. This has to be done accurately to avoid damage to the mating
components. Provision has also to be given to activate the SCM's lock down
system.
To achieve this a running tool has to be used. These can take one of two
forms of guidance. The first being guide wires and guide posts. The other
requires the ROV to guide the SCM and its running tool into a funnel that
surrounds the Landing base.

Running tool SCM (Guide Wire )

Balder SCM inside the running tool landing on to the landing base

The Running Tool is used to install and retrieve the SCM. It is a carbon steel
fabrication which locates over the SCM. An ROV-operated latch mechanism
interfaces with the top of the SCM's Podlock, which is designed for lifting the
module. At the top of the Running Tool a worm and wheel gearbox provides
the ROV (equipped with torque tool) with the means to tighten or release the
Podlock screw mechanism. This type of SCM running tool is used with guide
wires and guide posts to provide the guidance onto the landing base. As the
running tool and SCM are lowered by the workover vessels crane, it is
possible that the SCM could arrive on the landing base at an unacceptable
speed. This could course damage to the landing base or the SCM. To avoid
this the running tool is equipped with a 2 stage damping system.
The first stage acts as a shock absorber, decelerating the running tool before
it comes to land on the 2nd stage. This stage holds the SCM off of the landing
base so that no couplers are made up. With the running tool and the SCM in
this position, the cranes lift is released. The ROV will then open a valve on the
running tool. Opening this valve allows hydraulic fluid in the damper rams to
be vented. This allows the SCM to lower onto the landing base slowly so as to
make a good connection. On poorer designed running tools the vented oil
from the running tool is allowed to vent to sea. Apart from the obvious
pollution this causes, it also means that the dampers have to be recharged

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before they can be used again. (Troll project). The better designs the vented
fluid is released into a bladder barrier, where it is stored until the weight of the
RT/SCM is removed from the dampers. At this time the weight of the damper

pistons will draw the oil back in. ready for the next time. (Total ANE)

SCM Running Tool (SCMRT) Guide Funnel.

The Running Tool is used to install and retrieve the SCM. It is a carbon steel
fabrication which locates over the SCM and fits inside the SCMMB guide
funnel. A ROV-operated latch mechanism interfaces with the top of the
SCM's Podlock, which is designed for lifting the module. At the top of the
Running Tool a worm and wheel gearbox provides the ROV (equipped with

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torque tool) with the means to tighten or release the Podlock screw
mechanism.

Projects that utilise Guide wire Running tools include.

Troll, Alwyn North Extension (ANE), Balder and Blackback. The Foinaven
SCM is run on guide wires but does not use a running tool supplied by VG,
but uses a universal tool that is used for various component changes within
the system. The Diver installed Britannia SCM's are run on guide wires but
without a running tool.

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 Subsea isolation valve
When a product is produced from the platform it is pumped down a pipe to the
sea bed, then exported via a pipe line. Within 300M of the platform a valve is
fitted, to shut off flow in the event of an emergency.

What sort of emergency ?

In the event of an incident where the export pipeline or the production train
itself are damaged allowing hydrocarbons to be released to atmosphere,
production would be shut down de-pressurising the system and preventing
any more product from being released.
But the product that had already been exported would now be coming back
from the export line uncontrolled. This is what happened in the Piper field in
1988 with tragic results.
It is now a mandatory requirement that all production facilities that export
there product in this way must be protected. To achieve this a Ball valve is
placed in the export line 300 M from the facility. The valve is held open via
direct hydraulics. But if the pressure in the hydraulic line is vented then the
valve would close.

This function is ideal for direct hydraulic control, as there are few functions
(often only one) and the offset from the pressure source is only 300 to 400 M.

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 New Innovations
Vetco Gray Controls commitment to continuous product development and
research, has resulted in many new and exciting additions to our product
range. The new products have and are being developed to provide the
customer with options that can improve there productivity and reduce there
installation and running cost.

High Integrity Pipeline Protection System (HIPPS)

HIPPS makes it possible to reduce subsea pipeline project costs by up to

30% because of decreased pipeline thickness and material usage - without
compromising safety.
HIPPS incorporates autonomous functions for continuous monitoring of the
pipeline pressure and instantaneous shut down of the pipeline if the pressure
should rise to a pre-set threshold value.
The system basically consists of a choke to maintain a continuous pressure,
barrier valves to shut in if pressure increases and a high integrity control
module.

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 Pigging Operations
Pigs

A pig is a cylindrical unit that is pushed, pulled, blown or sucked up or down

the pipe line/flow line. There are a variety of different types of pigs that are
capable of many task.

Rubber pigs
This type of pig is a cylindrical lump of steel with a series of rubber flat rings
around it. The diameter depends on the diameter of the pipe that has to fit
them. It is used for generally cleaning of the pipe line, often pushed along by
the product flow but can also be used for new pipework de-watering. In this
mode it is pushed down the pipe line by nitrogen gas, pushing the water out in
front of it.

Scouring and Wire Pigs

This is similar to the rubber pig and is often used together. Instead of rubber
ring the pig is fitted with rings of hard wire. They are used for de-scaling and
polishing.

Intelligent Pigs
These pigs are self propelled. They can send back pictures, sound, infra-red
images and ultrasound. They can measure the wall thickness of the pipe,
carry out crack detection and all while the pipeline is in full flow production.
A pig is launched into the flow line from a pig launcher. This is located on the
platform. As it reaches the subsea end of the flowline facilities are made
within the manifold to return the pig up the other flowline by what means of
what is referred to as a pigging loop. Each end of the pigging loop is closed
off by a pigging valve. So as to allow the operators to know when the pig has
arrived at the manifold and open the pigging valve to send the pig into the pig
loop the manifold is equipped with pig detectors. These are movement
centres that are fitted on the outside of the pipework and can sense when the
pig passes. The information is sent back to the master control station which
sends up an alarm to inform the operators.

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 Appendix 1

Projects to date.

Production Well Control Projects

1981 BP Magnus 8 Well control Diver/RT Installation. Brit
1988 BP Don 4 Well control Diver Installation Brit
1990 Total ANE 3 Well control Diver/ROV Installation Brit
1992 Conoco Lyell 8 Well control Diver Installation Brit
1992 Exxon Zinc ? Well control ROV Installation USA
1993 Hydro Troll ? Well control Diver Installation Norg
1994 AHL Hudson 8 Well control Diver Installation Brit
1995 BP Foinaven 18 SCM’s ROV Installation Brit
1996 Saga Vigdis 15 SCM’s ROV Installation Norg
1996 Repsol Poseidon 3 Well control ROV Installation Spain
1996 Britannia 8 Well control Diver Installation Brit
1996 Esso Balder 15 Well control ROV Installation Norg
1997 BP Troika 6 Well control ROV Installation USA
1997 Chevron Alba 2 Well Control ROV Installation Brit
1997 Marathon Arnold 3 Well Control ROV Installatio USA
1998 Esso Blackback 3 Well Control ROV Installation Aust
1998 Troll Pilot Subsea Seprator ROV Installation Norg
1999 Petrobrass Marlin. 10 Well Control ROV Brazil
1999 Chevron Kuito 30 Well Control ROV Angola

Sub Sea Isolation Valve (SSIV) Controls

1988 Chevron Ninian 12 plus valves
1989 BP Ninian 1 Valve
1989 BP Magnus 1 Valve
1990 BP cleeton 3 Valves
1993 Texaco Strathspey 6 Valves
1997 Britannia 6 Valves
1998 Alba/Britannia 2 valves

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 Appendix 2
List Of Abbreviations.

Tree Related

PWV Production Wing Valve

PMV Production Master Valve
AMV Annulus Master Valve
AWV Annulus Wing Valve
XOV Cross Over Valve
COV Cross Over Valve
FCV Flow Cut Valve
MIV Methanol Injection Valve
PCVO Production Chock Valve Open
PCVC Production Chock Valve Close
CIV Chemical Injection Valve
SSSV Sub Surface Safety Valve
DHSV Down Hole Safety Valve
DHPT Down Hole Pressure and Temperature

BOP Blow Out Preventer

LRP Lower Riser Package
WOCS Work Over Control System

Manifold Related

PDV Production Diverter valve

PV Pigging Valve
SI Scale Inhibitor
CI Corrosion Inhibitor
CP Cathodic Protection

Control System related

SCM Sub Sea Control Module

SCP Sub Sea Control Pod (USA)
UTA Umbilical Termination Assembly
SEDB Sub Sea Electrical Distribution Box

Top SIDE Equipment

HPU Hydraulic Power Unit

PJB Platform junction Box
MCS Master Control Station
DCS Distributed Control System
PCS Platform Control System

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SES Sub sea Engineering Station
SMU Subsea Modem Unit
PSD Process Shut Down
ESD Emergency Shut Down
MCC Motor Control Cabinet
EPU Electrical Power Unit

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 Appendix 3

TYPES OF FACILITY -

Jack-up Drill Rig

Semi-submersible Drill Rig
Drill Ship
Tension Leg Platform (TLP)
Steel Jacket Platform
Concrete Gravity Base Platform
Floating Production Unit (FPU)
Floating Production and Storage FPSU or FPSO in the case of Foinaven
Dive Support Vessel (DSV)
Multi-support vessel (Floatel) (MSV)
Emergency Support Vessel (ESV) (Iolare)
Heavy Lift Barge (DB 102 M7000)
Pipe and Cable Lay Ships (Flex Installer Apache)
Rock Dumpers
Survey Vessels
Trenching Vessels
Supply Vessels
Standby Vessels

Jack-up Drill Rig

Typical Jack up Rig.

These units consist of a triangular main desk/hull. On each corner there is

fitted a retractable lattice leg, 200-300 ft. long. Once the rig has been floated
into its working position the three legs are lower down to the sea bed and are
then used to lift the hull/work desk out of the water. The drill rig itself is
located on a sliding platform so once in position it can be moved over the side
to its work position. This at times may be over a fixed platform riser area.

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The jack-up drill rig is only used in shallow water such as southern North Sea
gas fields.

Semi Submersible Rig.

For deeper water drilling the preference is to use a Semi submersible drilling
rig. These rigs are basically catamarans, with the deck raised up from the 2
hulls on legs. They are often self propelled. Once on location they can ballast
down to move the bulk of the mass of the vessel bellow the moving surface
water. This makes them very stable work platforms.

A Semi sub at rest in the Cromarty Firth

In very deep waters they can hold themselves in position using thrusters (DP
dynamic positioning). But in most cases are held in position by anchors with a
very wide spread. With recent developments in deep water production, Semi-
submecibles are now being used for production platforms.

Tension leg platform

Tension leg platforms are similar in construction to a Semi-sub, but instead of

blasting them down they are pulled down by multiple chains and as such are
no longer mobile.

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Steel Jacket Platform

The steel jacket platform s re the most widely used platform design. The steel
tubular tower on to which the decking and modules are attached, sits on the
sea bed and is held in place with piles. The use of steel tubes allows the
structure to be very flexible, allowing the structure to sway with the sea.

Gravity base platform.

Gravity based platforms like the steel jackets sit on the sea bed. Normally built
of concrete they can be completely built in shore before being floated into
position and ballasted onto the sea bed. There central column is often used to
store the produced crude prior to off load to a shuttle tanker.

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Floating Production and storage unit. (FPSU)

Floating production and storage units (FPSU) or Floating production and

offloading vessels (FPSO) are large ships, often converted from super
tankers. All the production systems normally found on a platform is located on
the main deck. The produced oil is stored in the hull until a shuttle tanker
offloads and takes it to the shore.
The FPSU is moored to the sea bed via a turret around which the entire
vessel rotates. The turret is also where all the sea bed interfaces such as the
flowline risers and the control umbilical enter the ship. Mostly used with
subsea control system fields but smaller units can be fitted with a Derek and
direct risers.

Multi support vessels.

Tern Alpha platform with the MSV Felicia in attendance

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MSV's often refereed to as floatels are used in fields during large scale
construction phases. There roll is to provide accommodation for the work
force, as well as work deck space and crainage. Normally large Semi-subs
with an automatic bridge link to the installation.

Heavy Lift barge.

These vessels are used for construction off shore and are the largest mobile
cranes in the world. The heavy lift record is currently held by the DB102 when
it lifted the Britannia integrated deck onto the jacket at a weight of.12,000
tones.

Pipe and Cable Laying Ships

The pipeline layer Norlift.

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Pipeline lay vessels like the Norlift and the Apache are used to lay pipelines
up to 24" dia. The steel pipes are constructed on 2 mile long piers before they
are coiled up onto the vessels vertical carousel. Once on location the pipe is
fed through a straightening system on the vessels stern before being laid on
the sea bed.

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