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www.xodusgroup.com
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Drill Site Plug n’ Play and The Reusable Control System
Gordon Anderson
22nd August 2017
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> What is Plug n’ Play?
– “conveys a message of interconnectivity and the ability to connect modular equipment in an
easy and effective way, to form a production system that is fit for purpose and rapid to
deploy”
> Plug n’ Play Aspiration:
– Rapid engineering & delivery of the project
– Full interconnectivity between modular subsea components
– Re-use of subsea equipment from field to field (the circular economy)
– Interoperability with present and future systems
– Flexibility to use a range of supplier specific subsea components
Drill Site Plug n’ Play
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> Key Assumptions
– UKCS
– 80/20 Rule (i.e. Design for majority, not all)
– Water Depth suitable for Diver intervention
– Minimal Fishing Protection
> Level 1 – Fundamental Design Philosophies
> Level 2 – High Level Equipment Functionality
Plug and Play Drill Centre
Drill Site Plug n’ Play
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> Layout - Manifold
> Construction - Diver+
> Subsea Xmas Tree - Standard / Basic
> Flow Management - Standalone Module
> Pressure / Temperature - 5000psi, 90°C (Prod.), 60°C (GL)
Level 1 – Fundamental Design Philosophies
Drill Site Plug n’ Play
Data reviewed from historic
developments across UKCS
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> Jumper Type - Unbonded flexible or Composite Pipe
> Production Jumper - 6” ID, 60m Long
> Gas Lift Jumper - 2.5” ID, 60m Long
> Connection System - Diver+ Quick Connect/Disconnect
Level 2 – Equipment High Level Functionality
Drill Site Plug n’ Play
Data reviewed from historic
developments across UKCS
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> Manifold Structure
– Standard design
– No test loop, metering or chemical injection
– Headers, branches and space for 2 x SCM
– Gravity based
– Slab-sided
> Flow Management Package
– Metering, Chemical Injection, Sampling
– Modular system to provide custom field
requirements
– Change-out modules as/if required
Level 2 – Equipment High Level Functionality
Drill Site Plug n’ Play
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> Key Objectives
– Guarantee equipment integrity
– Optimise offshore schedule
– Maximise vessel availability
> Solutions
– Monitored installation and recovery
– Gravity based structures
– Standard designs and installation methods
– Diver+ Quick Connect/Disconnect
– Subsea Jumper Carousels
Installation & Recovery
Drill Site Plug n’ Play
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Summary & Future Work
Drill Site Plug n’ Play
Summary
> There is an economic justification for plug n’
play drill site
> Technology is largely proven with little
development needed
> Requirement for greater monitoring during
installation, operation and recovery
Future Study Work
> Ownership model for re-usable equipment
> Installation methods that guarantee integrity
of components
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> What is the Reusable Control System?
– A system where all components are designed for recovery and re-use
– Designed to operate for 4-5 years before recovery / refurbishment / re-use
> Current practise combines topside and subsea equipment;
> Deploying the equipment at the drill site allows it to be recovered and easily moved to the next drill
site;
> Reusing the umbilical is a possibility however this study has concentrated on systems deployable
local to the drill site.
Reusable Control System
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> Expensive item of equipment to purchase and install;
> Considered to be a long lead item contributing to longer project executing times;
> Unlikely that the umbilical could be recovered and re-used multiple times;
> Umbilical failure would result in a full replacement being installed at considerable cost;
> Considerable cost to retrofit a J-tube to an existing host facility should there be no spare J-tubes
available to house the umbilical.
Reusable Control System
Benefits of removing the umbilical from a subsea control system
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The umbilical contains a number of hoses and cables providing the following services:
> Low and high pressure hydraulic supply lines;
> Chemical injection supply lines;
> Power supply lines;
> Communication supply lines.
What services does the umbilical provide?
Reusable Control System
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Block Diagram
Reusable Control System
Hydraulics
Unit
Subsea Control
Module
Chemicals
Unit
Subsea Tree
Power /
Communications
Unit
Signal Unit
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Power \ Communications Services:
> Example: EC-OG Subsea Power Hub
– Power generated by Ocean Current
– Power stored in batteries
– Communications Acoustic to a surface Buoy
– Dimensions: 5000 x 7000mm
– TRL 6.
> Example: OPT PB3 PowerBuoy.
– Power generated by Ocean waves
– Power stored in batteries
– Communications RS232, RS485 & Ethernet to payload and wireless or Satellite to host facility
– Dimensions: 12300 x 3300mm
– TRL 8.
Reusable Control System
Alternative options for providing the umbilical services
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Power \ Communications Services:
> Example: Current2Current C-Socket
– Power generated by Ocean Current
– Power stored in batteries
– Communications Acoustic to a surface Buoy
– Dimensions: 4000mm Height, 4250mm Diameter
– TRL 6.
Hydraulic Services:
> Subsea Hydraulic Power Unit;
– Example: Siemens SHPU
• 20 W Power Consumption
• Dimensions: 1690 x 2817 x 1092mm
• TRL 5.
> All Electric Tree.
Reusable Control System
Alternative options for providing the umbilical services
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Chemical Injection Services:
> Subsea Chemical Injection Unit;
– Example HAI Technologies SCIU
• 15kW pump
• Chemicals bunkered in a integrated subsea tank.
• Dimensions Pump Unit: 2800 x 2800 x 8500mm
• TRL 5
Combined System Option:
> Production Control Buoy
– Example: Proserv Buoy
• Communications/ Hydraulics / Chemicals located on the Buoy
• Power supplemented by a subsea power unit
• Communications via line of sight, 3G/4G or satellite
• Services supplied to the Tree via a down line
• Buoy and Surface Equipment TRL 9
Reusable Control System
Alternative options for providing the umbilical services
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Reusable Control System
Concept System Architecture
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Reusable Control System
Concept System Architecture
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Reusable Control System
Concept System Architecture
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Reusable Control System
Concept System Architecture
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> All concept options are deemed to be technically viable, demonstrating that there are several options for developing a reusable control system;
> The power requirements can be met using renewable power sources:
– Approximate peak power required 49kW, during start up;
– Normal operation approximate power required 100W;
– Renewable power sources can supply power ranging from 36kW to 600kW.
> High level costs for each type of architecture were generated for 10km Tie-back of the Future;
> Each concept option was assessed against the following criteria:
– System Robustness;
– Installability;
– Reusability;
– Maintenance Access;
– System Average TRL status;
– Cost Differential to least expensive.
Reusable Control System
Option Comparison
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Reusable Control System
Option
Criterion
System
Robustness
(3)
Installability
(2)
Reusability
(3)
Maintenance
Access
(1)
Average TRL
Status
(2)
Cost
Differential to
least
expensive (%)
(3)
Total
Weight
Score
√
Option Comparison
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Reusable Control System
Tie Back of the Future with Reusable Control System
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Reusable Control System
GA of The Tie Back to the Future with Reusable Control System
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Summary
> Reusable Drill Site Control Systems are feasible and an alternative to the umbilical;
> Equipment is better suited for re-use;
> Technology is in the latter stages of development.
Future Study Work
> Further study work into the communications network in terms of security and providing ESD
functionality;
> A study to look at optimising the power requirements of the subsea equipment.
Reusable Control System
Summary \ Future Work
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