OFF550 Subsea technology semester task 2015

Ørjan Bergum1

Abstract: Subsea development has in later times become more and more popular. By the use of subsea production
and processing structures situated on the seafloor, the hydrocarbons from multiple producing wells are combined
and brought to storage facilities either at surface, or onshore. This reduces the need of production rigs and ulti-
mately reduces the cost. In this paper, some of the main subjects involving subsea development are explained. The
introduction of some design elements in a hypothetical subsea development has also been chosen and explained
in this paper.

Keywords: Effective force · Hydrostatic pressure · Subsea · Production · Completion · X-mas tree · Control
system · Flow assurance · Barrier · FMECA · Reliability · Actuator

1 Introduction
For this paper, a hypothetical subsea field was given to develop. The field, which is a high pressure high tem-
perature (HPHT) field is located in the Norwegian sea, some 250 kilometers from shore. 32 wells are intended to
be drilled in three different reservoirs ranging from 2700m to 4850m below sea level (MBSL). The subsea system
lies at 285 MBSL, and is planned to produce to a floating production, storage and offloading (FPSO) vessel at
surface. The reservoirs consist of oil, gas and condensates, and it is estimated to have a reserve of 104 𝑀𝑆𝑚3 oil,
and 200 𝑀𝑆𝑚3 of gas. The pressure and temperature ranging from 680 to 790 Bar and 140 to 170 degrees Celsius
makes this classify as a HPHT field. In addition to these three reservoirs, a prospect located 40 kilometers to the
south has to be implemented for future tieback.
Following this brief introduction to the paper, section 2 gives the answer to tasks associated with the designing
and development of a subsea field.

2 Subsea system design

2.1 Riser forces

The basic forces in a vertical drilling riser is axial and radial forces. The main axial force the riser is exposed to
is the weight force of the riser, including internal fluid column, hanging from the top drive, or rotary table. This is
normally measured at the top of the riser, as this is where it is largest. The radial force comes from the hydrostatic
pressure of the water surrounding the riser. As the radial force acting on the riser is equal around the whole pipe

1
Ørjan Bergum
Student, Institute of Petroleum Technology
Email: Orjan_rb@hotmail.com
 OFF550 Subsea technology semester task 2015

at a given depth, the hydrostatic force will also act upon the riser in an axial direction. Due to the pressure differ-
ential between the fluid column inside the riser and the seawater outside, the radial force will act as buoyancy in
an axial direction. By combining these forces, axial force of the riser steel, axial force of the hydrostatic mud
column on the inner area of the riser, and the axial force of the water column on the outer area of the riser, a
formula for true and effective forces has been deduced. 𝑇𝑒 = 𝑇𝑡𝑟 – 𝑝𝑖𝐴𝑖 + 𝑝𝑒𝐴𝑒. While true tension usually is
measured at the top of the riser, and can be seen upon as what the hook load will show, the effective tension can
be calculated at any depth, and represents the “hook load” at that particular point. By setting the effective tension
to zero at the bottom, the true tension at bottom can be calculated by this formula.
𝑇𝑒 = 0 => 𝑇𝑡𝑟 = 𝑝𝑖𝐴𝑖 − 𝑝𝑒𝐴𝑒 [1]. First calculating the inner area of the riser 𝐴𝑖 = 0,193𝑚2 , the outer area of
riser 𝐴𝑒 = 0,223𝑚2 , the total are of steel 𝐴𝑠 = 0,03𝑚2 . Using density of steel=7,85 sg, water 1,00 sg, and mud
1,80 sg. Calculating the hydrostatic pressures of steel, water and mud at bottom, 𝑃 = 𝜌𝑔𝐻, 𝑃𝑠 = 24,26 𝑀𝑃𝑎,
𝑃𝑚 = 5,56 𝑀𝑃𝑎, 𝑃𝑤 = 2,80 𝑀𝑃𝑎. Here the height of steel and mud is set to the height of the drill floor, approx-
imately 30m above MSL. True tension on the bottom is then 𝑇𝑡𝑟 = 5,56𝑀𝑃𝑎 ∗ 0,193𝑚2 −
2,80𝑀𝑃𝑎 ∗0,223𝑚2 = 450𝐾𝑁. To calculate the tension on top, the force of the riser pipe hanging from the top
drive has to be added, 𝑇𝑡𝑟 = 450𝐾𝑁 + 24,26𝑀𝑃𝑎 ∗ 0,03𝑚2 = 1177𝐾𝑁. [1][2]

2.2 Equipment forces

The subsea structures are exposed to massive forces from the environment. At a depth of 285m below sea level,
the outer parts of the subsea equipment experiences 28 Bar pressure from the weight of water pushing down on it,
at a temperature of 4 degrees Celsius. As for the inside, the wellhead can in extreme cases experience up to several
hundred Bar and above one hundred degrees Celsius. As mentioned, the hydrostatic pressure of the overlaying sea
exerts a force upon the external area of the equipment in both an axial and radial direction. As the hydrostatic
pressure around a cross section of a deviated pipe differs due to depth, the umbilicals, flowlines and alternatively
production riser, stretching up the receiving structure, is experiences a force pushing them towards a lateral posi-
tion. Inside these pipes, and the x-mas tree as well, there is a large pressures and temperatures due to the production
of hydrocarbons from the reservoir. In this case the reservoir pressures and temperatures ranges from 680 to 790
Bar and 140 to 170 degree Celsius. If producing oil, this would mean that the inside of the equipment situated on
the seafloor will experience something like 500 Bars and above 100 degrees, due to the reservoir. The further
down in the well, the higher these numbers becomes. [1][2]

2.3 Field Design

Figure 1: Subsea design layout

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Ørjan Bergum

The production template consist of a four-slot drilling template, where three slots are in use, such that an
empty slot can be used for storage. On each of these active slots, a x-mas tree is attached which connects the
well to a manifold situated in the middle of the template. The x-mas tree also houses the tubing hanger which
holds the production tubing, flow control to regulate the well flow, and means of injecting chemicals into the
well. In addition to this, the production template also houses a control panel to connect and control the incoming
umbilical to each x-mas tree. Surrounding the production template is a protection structure. This is a large frame
structure encapsulating the modules to protect them from physical forces such as trawling nets, thus being very
important on the Norwegian continental shelf (NCS). Riser bases are there to secure the risers (production and
umbilicals) to the seafloor, and should include a floating system where the riser are able to bend and extend ac-
cording to the movement of the FPSO (Floating Production Storage and Uploading). A tie-back was included to
accommodate for potential development of a nearby prospect, situated 40 km south of this layout. This system
makes it easier to connect a new reservoir to the subsea infrastructure of an existing field. An umbilical is a pipe
supplying the production template with electricity, hydraulics and the possibility of chemical injection. Ranging
from 15𝐾𝑚2 to 45𝐾𝑚2 , the reservoirs sizes demands large numbers of umbilicals, tens of kilometers long. This
also applies to the flowlines. These are tubings transporting the produced fluid to a processing unit, manifold, or
straight up to a receiving facility. For this layout, a subsea-processing unit was not included. An extra manifold
was planned to gather all the produced hydrocarbons before exporting it to surface through a single, or fewer
flowlines [3]. After drawing this subsea layout, I realized that the extra manifold was not necessary, as the FPSO
should have no problem accommodating a large number of umbilicals and flowlines. The extra manifold was put
there solely to decrease the number of flowlines going up to the ship. In addition, there should have been double
sections of flowlines to allow for future cleaning and inspections “Pigging”. Upon reviewing the drawing, the
tieback system was found to be situated incorrectly. This was sorted out by adding a compass in the upper right
corner.

2.4 Upper completion

The upper completion starts at the interface with the lower completion. The end of the production tubing is
therefor the lowest component of the upper completion. As parts of the upper completion, the following compo-
nents have been included. 7” production tubing, removable production packer, down hole safety valve, side pocket
mandrels, annular safety valve, sliding sleeves, landing nipples, wellhead, and tubing hanger. The production
tubing is essential for guiding produced fluid and gas up to the x-mas tree, and thus runs the whole length from
just above the reservoir, up to the x-mas tree, in this case situated at the seafloor. To isolate the annuli between the
production casing and tubing, a removable production packer is needed just above the reservoir. The packer pre-
vents formation fluid and gas to enter the annuli above the packer depth, thus not filling up the annuli all the way
to surface, potentially damaging the casing. With plans of a horizontal x-mas tree, the tubing must be pulled in
case the x-mas tree needs to be removed, making a removable packer an advantage. Another essential component
of the upper completion is a subsurface safety valve (SSSV). This is a failsafe barrier whose main function is to
prevent an uncontrolled flow of formation fluid, flowing up through the production tubing. A surface-controlled
subsurface safety valve (SCSSV) can be seen upon as a flap or ball, which, when closed seals the tubing shut, and
chokes the flow. For the flap to be open, and fluids flow past it, a minimum hydraulic pressure exerted on the
SSSV is needed. This is applied by a hydraulic hose run from the x-mas tree. If this hydraulic pressure is lost, or
the force of the flowing fluid becomes too large, the flap will close, choking the flow. The location of these valves
is subject to several limiting factors, as it can not be placed at a depth where the hydrostatic pressure of the hy-
draulics becomes sufficient to open the flap, nor can it be placed too high because of potential hydrates forming,
due to the joule-Thomson effect [4]. In similar manner as the SCSSV, an annular safety valve (ASV) is a failsafe
barrier intended to prevent an uncontrolled flow of hydrocarbons up through annulus. Working similarly as the
SCSSV, the ASV is particularly important if the well is considered for gas-lift, as is on this field. Side pocket
mandrels are pockets inside the completion in which it is possible to place valves for chemical injection or gas-
lift. This is a part of the completion with a machined side pocket in the tubing, where the gas-lift valve is slid into,
after removing an already in-place dummy. This enables gas, injected into the A-annulus, to flow into the tubing.
Downhole gauges are various sensors providing continuous monitoring of the wells characteristics. Temperature
and pressure are typically parameters used to model and predict the behavior of the well and reservoir. These
gauges sends real time data to rig, and are connected to surface by either fiber-optical or electrical wires. The
wellhead hangs off the conductor beneath the x-mas tree, and is needed as it is the hang-off for the rest of the
casing string. In addition to this, the wellhead also acts as pressure containment and isolation for the well and
annuluses, making it possible to access and control the annuluses, and attaching a well pump. At the very top of
the upper completion is the tubing hanger. This component sits either inside, or beneath the x-mas tree, and acts
as both the connection between the tubing and x-mas tree, as well as the hang-off for the tubing [3][5].

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 OFF550 Subsea technology semester task 2015

Figure 2: Upper completion

2.5 X-mas tree sketch not included

For this field a horizontal x-mas (HXT) tree was chosen. A x-mas tree system is built up of several parts. The
most importantly mentioned, x-mas tree assembly, valves and chokes, protection structure, flow control module,
and tubing hanger. The purpose of the x-mas tree is to act as the barrier between well and environment, and as a
mean of directing, isolating and controlling the flow, when in a production scenario. The x-mas tree also allows
access the well for workovers, and for performing and controlling various substance injections like chemicals, gas
and water. I look upon the relevant reservoirs as fairly complex, in addition to them containing not only gas, but
oil and hydrates as well. With this in mind, the x-mas tree is designed for frequent interventions and workovers.
In such a situation, a HXT is preferable, as it does not require the removal of the tree to access the wellbore, as is
the case with vertical x-mas trees (VXT). As the tubing hanger is situated inside the HXT, opposed to underneath
in the case of VXT, makes for easier pulling of the tubing to do potential recompletions, without pulling the tree.
Both saving time and money. With larger completion sizes preferable due to the possibility of higher flow rate and
larger intervention tools, the HXT accommodates for this by allowing for up to 7” production tubings. Where as
the VXT, in most cases, is limited to a 5” production casing. [3]

Figure 3: Horizontal x-mas tree

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Ørjan Bergum

2.6 FMECA

A failure mode effect and criticality analysis (FMECA), is an analysis performed to help mapping how different
components in a systems may fail, which effect this may have on other component in the system, and the effects
on the system as a whole. Starting by categorizing all the components of the system, and how they are connected,
a list or block diagram can be formed. For each of these components, a FMECA worksheet is filled out. Possible
failure modes and mechanism shall be listed, together with how they can be detected, and the local and global
effect of these. Finally, a risk analysis should be made, in addition to possible risk reducing measures. Failure
modes describe the fault of the component, with the failure mechanism station to why the problem occurred. Local
and global effects refers to the effect such failures might have on the local components and the system as whole,
respectively.

System: Subsea production system Performed by: Ørjan Bergum

Ref. Drawing: Figure [1] Date:10.11.15 Pages: 1 of 1

Table 1: Subsea FMECA work sheet

2.7 Subsea system reliability

Figure 4: Subsea production system reliability block diagram

Reliability of a system is the possibility of all components to “perform its intended function for a period of
time”. In a system with four components where every component has to be functioning for the system to operate,
we say that they are connected in series. The reliability of each component is multiplied to give the systems total
reliability (ℎ𝑠 ). In some cases, there are several components doing the same function, or working as a backup. If
one of the components fails, the other components will still function, making sure the system still operates. This
type of parallel connection (ℎ𝑝 ) can be calculated by subtracting the product of components failure probability,
from one. From using ℎ𝑠 and ℎ𝑝 , the reliability of a combined system (ℎ) can be calculated as shown below.
Parameters 𝑃1 to 𝑃8 are all assumed values of unit reliability.

𝑆𝑦𝑠𝑡𝑒𝑚 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 [ℎ] = 𝑃1 ∗ 𝑃2 ∗ 𝑃3 ∗ 1 − [(1 − 𝑃4 ) ∗ (1 − 𝑃5 )] ∗ 1 − [(1 − 𝑃6 ) ∗ (1 − 𝑃7 )] ∗ 𝑃8

ℎ = 0,98 ∗ 0,99 ∗ 0,98 ∗ 1 − [(1 − 0,96)2 ] ∗ 1 − [(1 − 0,99)2 ] ∗ 0,97 = 0,9207 = 92,07 %

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 OFF550 Subsea technology semester task 2015

2.8 Barriers

“Barriers are used to prevent leakages and reduce the risk associated with drilling, production and intervention
activities.” [6] The main functions of a barrier is to prevent hydrocarbons or water leak out into the external envi-
ronments, either that being the formation, or surface. A barrier should also be able to stop, and shut inn the hydro-
carbons in the well, in the event of an emergency. Barrier elements are the single element components used to
make up a barrier system, from now on referred to as “barrier”. A barrier element itself is not capable of stopping
the flow of hydrocarbons, which is why they must be compiled into a larger barrier system to ensure the whole
well is protected. If a barrier system is breached, gas, fluid, and pressure may travel freely up the well to surface,
and well integrity is lost. This may result in worst cases result catastrophes like in blowouts, environmental issues,
and casualties. Due to the seriousness of such a situation, there is requirements to implement both primary and
secondary barriers on operations on the NCF. The primary barrier acts as the main and most important barrier. The
secondary barrier acts as a backup barrier in case there is a breach or failure in the primary barrier. In a producing
well, the primary barrier mainly consists of elements in direct contact with the producing hydrocarbons (HC).These
can include, in-situ formation, production casing and cement, production packer, completion string, DHSV, and
wellhead. In-situ formation stress acts as a barrier element preventing the reservoirs hydrocarbons migrating up-
wards through the formation, thus forcing it into the well. Furthest down in the well, the production casing and
cement prevents HC from migrating back into the formation and surface, potentially into water aquifers with per-
meable contact to the sea. Inside the production casing, the production packer prevents access into the A-annulus,
forcing the flow into the completion string, containing it from the external environment. Further up the completion
string, the last primary barrier is located. The down hole safety valve, described earlier, enables allows for con-
trolling the flow through the completion string, by either stopping it completely or allowing full flow. When closed,
the primary barrier contains the full flow from the reservoir, and provides integrity. Barrier elements making up
the secondary barrier may include, in-situ formation, production casing and cement, liner hanger- and tie-back
packer, intermediate casing, production casing hanger, tubing hanger, wellhead, and x-mas tree. In the following
description, a liner is not implemented. As with the primary barrier, the in-situ formation is the first barrier element,
starting at production packer depth, preventing migration through formation. Above this point, the production
casing and cement provides integrity up to a potential liner packer, liner, and tie-back packer. If no liner is imple-
mented, the production casing prevents flow to the B-annulus, and runs all the way up to the next barrier element
being the production casing hanger. The casing hanger hangs in the wellhead, which is the flow- and pressure-
containing interface between casing and x-mas tree. Inside the x-mas tree the annulus master valve (AMV), pro-
duction master valve (PMV), and tubing hanger is located. All three being individual barrier elements categorized
as the subsea tree. In addition to the primary and secondary well barriers described, some other equipment may
have single barrier elements added, such as double block and bleed valves. A block barrier is used to isolate an
area in between two blocks put in a series. As requirements state that one have to be able to confirm a good seal,
a bleeding valve is included so to confirm by bleeding and monitoring the pressure. In a double bleed and block,
two blocks are put in series for each unit, to have a backup if one fails. [6] [7]

Figure 5: Primary and secondary barrier

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Ørjan Bergum

2.9 Flow Assurance

Flow assurance is the mean of achieving best possible and continuous hydrocarbon flow through the pipelines
and riser. With the reservoir containing multicomponent hydrocarbons and water, in addition to the pressure and
temperature drop when producing the well or flowing through pipes, the fluids may form physical barriers which
blocks or chokes the pipeline. As downtime on a rig and even slight reduction in production may cause large
economical losses, the prevention of such formings are important to keep at a minimum. Flow assurance are the
means of preventing or reduce this. A few of the main challenges are the depositions of hydrates, wax, scale, and
asphaltenes, together with corrosion, and erosion due to sand production. These are only a few of the many flow
assurance challenges. The deposition of hydrates is possibly the largest of these challenges. When both water and
small HC-molecules are present at a temperature and pressure below approximate values, water crystals may start
to form, called hydrates. If the hydrates are allowed to grow, they will not only reduce the flow of HC, but may
also block the entire pipe. To prevent hydrate formation, maintaining a pressure or temperature higher than the
maximum values at which hydrates forms. One can also periodically inject inhibitors that lowers the freezing
temperature of the present water. Hydrates are normally not a problem in HPHT wells, where the pressure and
temperature stays above the critical point. When transporting hydrocarbons through seabed pipes over longer dis-
tances though, the ambient temperature of the sea and friction pressure loss in the pipe, may lower the values
significantly. Deposition and buildup of wax is another occurring problem. This is especially relevant for reservoirs
containing crude oil, but can also happen with lighter oil. A combination of hydrocarbon composition, high wall
friction in pipes, and the fluid temperature dropping lower than a critical value due to ambient temperature, wax
may start to form and build up. Same as with hydrates, this can lead to a buildup on the inside of the pipe wall,
eventually reducing the inner diameter (ID) of the pipe, reducing flow and plug it completely. Because wax par-
ticipation is highly temperature dependent, good isolation of the pipes is an effective method of preventing wax.
One can also use chemical injection like dispersants to prevent the wax crystals from attaching to each other and
building up.[8] With the high temperature of HPHT wells, this is normally not a problem during production, but
must be taken into account when designing long flow pipes to onshore facilities. Participation of salts in the well
is called scaling. Due to pressure and temperature drop, brine can become supersaturated with minerals and deposit
scale on imperfections in pipe and valves. As with hydrates and wax, this reduces the ID of the pipe, causing
reduces flow or blockage. Depending on the type of scaling occurring, milling, jetting, and chemical dissolution
are remediations to remove it. Often it is expensive and time consuming to remove scaling, making it important to
prevent buildup of scale as best possible. For this, continuous or periodic injection of scale inhibitors can be used.
In reference to the selected HPHT field, scaling is the most eminent challenge for flow assurance. For this field,
continuous injection of scale inhibitors into the well is selected. This is down to the expectations of a significant
water cut, in addition to a large pressure and temperature drop due to fairly deep reservoirs. The high pressure of
the reservoirs in addition to high flow rate and fluid velocity, can also cause heavy erosion in pipes and valves if
the well produces sand. By adding sand control to the lower completion, the sand production can be minimize to
accommodate for higher fluid velocity and flow rate. This is especially important in lower diameter pipes, where
higher fluid velocity is needed to achieve desired flow rate. In addition, good isolation and the possibility of elec-
trical heating of the subsea pipes and equipment situated on the seafloor is beneficial. As the temperature of the
NCS sea at bottom drop below 4 degrees Celsius, a longer shut-in situation can lead cool down of hydrocarbons
in the subsea system, leading to the formation of hydrates or wax. Though this is not a frequent occurring situation
at this field, it needs to be taken into account. [9][10]

2.10 Control Method

With large distances separating the people operating the subsea equipment, remote means of control the subsea
equipments functions are needed. Partially this is done by remote operating vehicles (ROVs), steered by a people
top-side, but mainly these are operated by a subsea control system. By using hydraulics, electricity or/and signals,
control systems enables for remotely operating valves, actuators, and other components in the subsea equipment,
through umbilicals from a rig/vessel. There are several different control methods available.
The direct hydraulic (DH) method supplies each actuate valve with hydraulic through a dedicated flowline. This
is a cheap and reliable method, but acquires large umbilicals and has low response time. A similar method is the
piloted hydraulic (PH). This method is based upon the DH, but adds an accumulator to the system close to the x-
mas tree, which is operated by hydraulics or electronics, to reduce response time for those actuator valves requiring
fast closing. Both the DH and PD are systems best suited for single, or few well scenarios. They are best suited in
shallow waters, with short tie-backs, due to large and heavy umbilicals. Direct electro hydraulic (DEH) is a third
method used. Again based upon the two previous, having dedicated flowlines and accumulators, this method in-
cludes the use of a subsea control module (SCM) to “control and monitor subsea instrumentations and actuators”
[11]. With an electrical and hydraulic control system topside, and a SCM situated on the x-mas trees and manifolds,
the SCM distributes low pressure (LP) and high pressure (HP) directly to the local valves. Here a latched function

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 OFF550 Subsea technology semester task 2015

is implemented which removes the need of continuous signal or pressure to keep the actuator valves open, using
less volume and capacity. By also branching together the control of the actuator valves in the x-mas tree and
manifold, fewer and simpler umbilicals are needed. Together with making use of the same features as PH, it allows
for fast response to dedicated valves, longer tiebacks and deeper water production. For this HPHT field, the electro
hydraulic multiplexed (EH-MUX) method has been selected. This is a system that subsea vise is similar in func-
tions to the DEH, but uses a master control station (MCS) and subsea control unit (SCU) on topside to integrate
the hydraulic and electronic power units, and send multiplexed electrical control signals to the SMCs. All data and
signals can therefor be sent through few umbilicals down to a subsea distribution unit (SDU), which branches the
umbilical to each SCU. The EH-MUX is able to transport large amounts of data, making it suitable for real time
controlling and monitoring of components and instruments. Fewer and smaller umbilicals, real time response,
together with LP and HP supply, and subsea accumulators, makes it possible to accommodate for longer tiebacks,
and simplifies controlling of multiwell developments, which is the main reason it has been chosen for this field.
All-electric (AE) systems are also available. The AE method uses electric motors to operate actuator valves, elim-
inating the need of hydraulics and accumulators, thus simplifying the system. Good data transfer and small umbil-
icals makes it suitable for long tiebacks and multiwell development. Though the cost of this system is fairly high,
this would be a good alternative to the EH-MUX chosen. [11][12]

2.11 Actuators

An actuator is a hydraulically or electrically operated motor used to move a mechanism. In this case, the actuator
is hydraulically operated by using a compression chamber and a spring on opposite sides of a piston, to open or
close a gate valve. A certain amount of hydraulic pressure has to be applied on the piston side to open the valve.
If this pressure is lost, or bled, the spring should be designed to have enough force to close the valve automatically.
By stating that the force of the closed spring [𝐾𝐶 ] should be equal to or larger than the resultant vertical force
acting on the piston, we end up with a formula to calculate the minimum spring force [𝐾𝐶𝑚𝑖𝑛 ] needed to automat-
ically close the valve. [10]
𝐾𝐶𝑚𝑖𝑛 = 𝑃𝑜 𝐴 + µ𝐹𝑔 + 𝐹𝑠 − 𝑃𝑅 (𝐴 − 𝑎) − 𝑃𝑤 𝑎 = µ𝐹𝑔 + 𝐹𝑠 + 𝑎(𝑃𝑅 − 𝑃𝑤 )
𝜋
𝐹𝑔 = ∆𝑃 ∗ 𝐴𝑤𝑏 = ∆𝑃 ∗ 𝐷𝑠 2
4

Here [𝐹𝑔 ] is the vertical force component from the pressure differential [∆𝑃] across the valve. Shut-in pressure
is equal to the flowing wellhead pressure given at 790 Bar, wellbore diameter [𝐷𝑠 ] chosen to be 7 inches, and
pressure in the outside chamber assumed equal to the inner chamber when closing. [10] By assuming the param-
eters, the result becomes: 𝑃𝑜 = 𝑃𝑅 = 6,9 𝑀𝑃𝑎, 𝑃𝑤ℎ𝑠 = 𝑃𝑤 = 79 𝑀𝑃𝑎, ∆𝑃 = 𝑃𝑤 − 𝑃𝑎𝑡𝑚 = 79 𝑀𝑃𝑎, 𝐹𝑠 =
𝜋 𝜋
40 𝐾𝑁, 𝐹𝑔 = ∆𝑃 ∗ 𝐷𝑠 2 = 79 𝑀𝑃𝑎 ∗ 0,17782 𝑚 = 1975𝐾𝑁, µ = 0,1, 𝐴 = 0,07𝑚2 , and 𝑎 = 0,0007𝑚2 .
4 4

𝐾𝐶𝑚𝑖𝑛 = 0,1 ∗ 1975 ∗ 103 + 40 ∗ 103 + 0,0007(6,9 ∗ 106 − 79 ∗ 106 ) = 187𝐾𝑁

These calculations shows that the spring must be designed to deliver a minimum force of 187 KN to be able to
automatically close the gate valve.

Figure 6: Actuator cross-section

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Ørjan Bergum

2.12 Hydraulic power unit

A hydraulic power unit (HPU) can be seen upon as a surface accumulator, providing the control system with a
low and high pressure hydraulic supply. The HPU needs to be able to supply enough pressure for actuators to
overcome the forces of the pressure and spring, in order to open the valve. When the valve is shut, both spring
force, friction force and the pressure force from the well acts as opposing forces to the opening of the valve. By
first calculating the pressure needed in the piston side of the actuator [𝑃𝑏𝑜 ], then subtracting the friction pressure
drop from the hydraulic pipe length [ΔPfi ] and adding the achieved hydrostatic pressure from the hydraulic, the
pressure requirements of the topside HPU can be calculated [𝑃𝐻𝑃𝑈 ]. Assumed Laminar flow in hydraulic pipe. [13]

𝐾𝑐 + µ𝐹𝑔 + 𝐹𝑠 + 𝑃𝑅 (𝐴 − 𝑎) + 𝑃𝑤 𝑎
𝑃𝑏𝑜 =
𝐴

ρh 0,8
( ) ∗ Q1,8 ∗ µh 0,2
ρw
ΔPfi = ∗𝑙
90163 ∗ IDh 4,8

𝑃𝐻𝑃𝑈 = 𝑃𝑏𝑜 + ρh 𝑔ℎ − ΔPfi

By the exception of the spring force 𝐾𝑐 , which has been obtained as 𝐾𝐶𝑚𝑖𝑛 from the previous calculation, the
required parameters are either stated in section 2.11, or assumed as following,
𝑆𝑝𝑟𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒, 𝑐𝑙𝑜𝑠𝑒𝑑 = 𝐾𝑐 = 187𝐾𝑁,
Kg
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐𝑠 = ρh = 1055 3,
m
Kg
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑤𝑎𝑡𝑒𝑟 = ρw = 1000 3,
m
l
Flow rate = Q = 30 ,
𝑚𝑖𝑛
𝑉𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐𝑠 = µh = 3,0𝑐𝑃,
𝐼𝑛𝑛𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑝𝑖𝑝𝑒 = IDh = 1,0 𝑖𝑛,
m
𝐺𝑟𝑎𝑣𝑖𝑡𝑦 = 𝑔 = 9,81 2 ,
s
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑢𝑚𝑏𝑖𝑙𝑖𝑐𝑎𝑙 = 𝑙 = 4000𝑚,
𝑊𝑎𝑡𝑒𝑟 𝑑𝑒𝑝𝑡ℎ = ℎ = 285𝑚

187 ∗ 103 + 0,1 ∗ 1975 ∗ 103 + 40 ∗ 103 + 6,9 ∗ 106 (0,07 − 0,0007) + 79 ∗ 106 ∗ 0,0007
𝑃𝑏𝑜 = = 137 𝐵𝑎𝑟
0,07

1055 0,8
() ∗ 301,8 ∗ 3,00,2
ΔPfi = 1000 ∗ 4000 = 26 𝐵𝑎𝑟
90163 ∗ 1,04,8

𝑃𝐻𝑃𝑈 = 137 + 1,055 ∗ 0,0981 ∗ 285 − 26 = 140,5 𝐵𝑎𝑟

If the operating pressure of the HPU is given to be 𝑃𝑡𝑜𝑝 = 3000 𝑝𝑠𝑖 = 207 𝐵𝑎𝑟, and the piston length re-
quired to open the valve is assumed to be 𝑙𝑝 = 0,3 𝑚, we can calculate the volume of hydraulics needed at oper-
ating pressure.
𝑃𝑏𝑜 = 𝑃𝑡𝑜𝑝 + ρh 𝑔ℎ − ΔPfi = 210,5 𝐵𝑎𝑟

𝐾𝑐 + µ𝐹𝑔 + 𝐹𝑠 + 𝑎(𝑃𝑤 − 𝑃𝑅 )
𝐴= = 0,03 𝑚2
(𝑃𝑏𝑜 − 𝑃𝑅 )
𝑉 = 𝐴 ∗ 𝑙𝑝 = 0,009 𝑚3 = 9 𝑙𝑖𝑡𝑒𝑟𝑠

9
 OFF550 Subsea technology semester task 2015

References
[1] Nergaard, A. (2015) Effective Force; Fiction or Reality? (SPE-174785-MS). Retrieved from
https://uis.itslearning.com/file/download.aspx?FileID=1254968&FileVersionID=-1&ChildID=-1

[2] Sparks, C. P. (2009) Basic Principles and Simplified Analyses, Fundamentals of Marine Riser Mechanics.

[3] http://subsea1.com/index/overview

[4] https://en.wikipedia.org/wiki/Downhole_safety_valve

[5] https://en.wikipedia.org/wiki/Completion_(oil_and_gas_wells)

[6] https://www.norskoljeoggass.no/Global/2013%20Dokumenter/Andre%20vedlegg/INTRODUC-
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[7] Norsok Standard D-010, Rev.4, June 2013

[8] http://petrowiki.org/Models_for_wax_deposition_in_pipelines

[9] http://www.diva-portal.org/smash/get/diva2:648700/FULLTEXT01.pdf

[10] Nergaard, A. (2009). Basic Subsea Hydraulics Design, Subsea Control Systems MOM 320.

[11] Husby A. & Morgan R. (2011) Subsea - Building Blocks.

[12] Bai, Y & Bai, Q. (2012) Subsea Engineering Handbook.

[13] Gabolde, G. and J.-P. Nguyen, Drilling Data Handbook 8th ed. 2006: Institut Francais du Pétrole Publica-
tions.

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